INSTALLATION AND OPERATING

INSTRUCTIONS

Models HD101–HD401
Types H & WH

WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and

liquids or other combustible materials in the vicinity of this or any other appliance.
To do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the variable speed pump or in a safe
place for future use.

Effective: 03-31-21
Replaces: 01-29-21
P/N 241356 Rev. 8
Revision 8 reflects the following changes:
Updated " Natural Draft Vertical Venting System Installation" section, NOTE added before figure 20 on page 23.
Table R: Updated "100 PPM" to "150 PPM" for Hi-Fire for nat & pro.
Updated "Quarterly" maintenance section, bullet number 4 added on page 43.

2
 CONTENTS
1. WARNINGS ............................................................. 4 6. WIRING DIAGRAMS............................................. 33
Pay Attention to these Terms................................... 4 Models HD101-HD151 Type WH1 ON/OFF........... 33
2. BEFORE INSTALLATION....................................... 5 Models HD101-HD151 Type H3 (2-Stage)............. 34
Product Receipt....................................................... 5 Models HD201-HD401 Type WH1 (ON/OFF)........ 35
Model Identification.................................................. 5 Models HD201-HD301 Type H3 (2-Stage)............. 36
Ratings and Certifications........................................ 5 Model HD401 Type H3 (2-Stage)........................... 37
Installations at Elevation.......................................... 5 7. PRE-START-UP..................................................... 38
Component Locations.............................................. 6 Filling System-Heating Heaters............................. 38
General Information................................................. 7 Domestic Hot Water Heaters................................. 38
3. GENERAL SAFETY................................................. 8 Inspect Venting System:........................................ 38
Time/Temperature Relationships in Scalds.............. 8 Pre-Start-Up Check................................................ 38

4. INSTALLATION........................................................ 9 8. INITIAL START-UP................................................ 38

Installation Codes.................................................... 9 Tools Needed......................................................... 38
Equipment Base....................................................... 9 Preparation for Start-Up......................................... 38
Clearances............................................................... 9 Start-Up.................................................................. 38
Conventional Combustion Air Supply..................... 10 Main Burner Adjustment......................................... 39
Combustion and Ventilation Air.............................. 11 Gas Valve Adjustment............................................ 40
Water Piping........................................................... 12 Gas Type Conversion on Valve.............................. 40
Hydronic Heating................................................... 13 Safety Inspection................................................... 41
Domestic Hot Water Piping.................................... 14 Follow-Up............................................................... 41
Gas Supply............................................................ 17 9. POST START-UP CHECK.................................... 41
Electrical Power Connections................................ 18 Air Filter Inspection/Removal................................. 42
Venting................................................................... 20 Heat Exchanger Removal...................................... 42
Outdoor Installation................................................ 27 10. MAINTENANCE..................................................... 43
5. CONTROLS............................................................ 29 Suggested Minimum Maintenance
Ignition Control Module.......................................... 29 Schedule:...................................................... 43
Outdoor Air Reset Temperature Controller............. 29 11. TROUBLESHOOTING.......................................... 44
Digital Temperature Control .................................. 31
12. ILLUSTRATED PARTS LIST................................ 45
High Limit (Manual Reset)..................................... 31
High Limit – Auto Reset (Optional)......................... 31 13. IMPORTANT INSTRUCTIONS FOR THE
Flow Switch............................................................ 32 COMMONWEALTH OF MASSACHUSETTS..... 51
High and Low Gas Pressure Switches (Optional).. 32
Low Water Cut Off (Optional)................................. 32

3
1. WARNINGS
Pay Attention to these Terms
Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial
DANGER
A  property damage if ignored.

WARNING
Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or
A  substantial property damage if ignored.

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product
CAUTION
A  or property damage if ignored.

CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could
CAUTION
cause minor personal injury or product or property damage if ignored.

Indicates special instructions on installation, operation, or maintenance which are important but not related
NOTE
to personal injury hazards.

A  DANGER: Make sure the gas on which the heater will A  WARNING: To minimize the possibility of improper
operate is the same type as that specified on the heater operation, serious personal injury, fire, or damage to
rating plate. the heater:

A  WARNING: Should overheating occur or the gas • Always keep the area around the heater free of com-
supply valve fail to shut, do not turn off or disconnect bustible materials, gasoline, and other flammable liquids
the electrical supply to the heater. Instead, shut off the and vapors.
gas supply at a location external to the heater.
• Heater should never be covered or have any block-
WARNING: Risk of electrical shock. More than one
A  age to the flow of fresh air to the heater.
disconnect switch may be required to de-energize the
equipment before servicing. A  WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified service
A  WARNING: This unit contains refractory ceramic technician to inspect the heater and to replace any part
fiber (RCF) insulation in the combustion chamber. RCF, of the control system and any gas control which has
as manufactured, does not contain respirable crystalline been under water.
silica. However, following sustained exposure to
very high temperatures (>2192ºF / 1200ºC), the RCF A  CAUTION: Operation of this heater in low-
can transform into crystalline silica (cristabolite). temperature systems requires special piping. Harmful
The International Agency for Research on Cancer internal condensation will occur if the inlet water
(IARC) has classified the inhalation of crystalline temperature does not exceed 105°F. Warranty claims will
silica (cristabolite) as carcinogenic to humans. be denied when condensation occurs.

When removing the burners or heat exchangers, take CAUTION: If this heater is to be installed above
precautions to avoid creating airborne dust and avoid
A 
radiation level, it must be provided with a low water cut-
inhaling airborne fibers. When cleaning spills, use wet off device at the time of heater installation.
sweeping or High Efficiency Particulate Air (HEPA)
filtered vacuum to minimize airborne dust. Use feasible CAUTION: If this heater is to be installed in a
engineering controls such as local exhaust ventilation or
A 
negative- or positive-pressure equipment room, there
dust collecting systems to minimize airborne dust. Wear are special installation requirements. Consult factory for
appropriate personal protective equipment including details.
gloves, safety glasses with side shields, and appropriate
NIOSH certified respiratory protection, to avoid inhalation
A  CAUTION: This heater requires forced water
of airborne dust and airborne fiber particles.
circulation when the burner is operating. See minimum
and maximum flow rates, Table E and Table F. Severe
damage will occur if the heater is operated without
proper water flow circulation.

4
2. BEFORE INSTALLATION Model Identification
Raypak strongly recommends that this manual be re- The model identification number and heater serial number
viewed thoroughly before installing your Hi Delta heater. are found on the heater data plate located on the right
Please review the General Safety information before side jacket of the heater. The model number will have the
installing the heater. Factory warranty does not apply to form H3-HD101 or similar depending on the heater size
heaters that have been improperly installed or operated and configuration. The first group of characters in the
(refer to the warranty at the back of this manual). model number identifies application and firing mode (H3
Installation and service must be performed by a qualified = 2-stage Hydronic Heating System, WH1 = on/off Hot
installer, service agency or the gas supplier. If, after Water Supply System). The last three places identify the
reviewing this manual, you still have questions which size of the heater.
this manual does not answer, please contact your local
Raypak representative or visit our website at www.raypak.
com. Ratings and Certifications
Thank you for purchasing a Raypak product. We hope you Standards:
will be satisfied with the high quality and durability of our • Gas-Fired Low Pressure Steam and Hot Water
equipment. Heaters, ANSI Z21-13 • CSA 4.9 - latest edition
• Industrial and Commercial Gas-Fired Package
Product Receipt Heaters, CAN 3.1 - latest edition
A WARNING: Pump motors should NOT be supported • Gas Water Heaters, ANSI Z21.10.3 • CSA 4.3 - latest
by any type of stand or support from above due to edition
possible misalignment of pump and motor which may
occur. All Raypak heaters are National Board registered, and
design-certified and tested by the Canadian Standards
On receipt of your heater it is suggested that you visually Association (CSA) for the U.S. and Canada. Each heater is
check for external damage to the shipping crate. If the constructed in accordance with Section IV of the American
crate is damaged, make a note to that effect on the Bill of Society of Mechanical Engineers (ASME) Heater Pressure
Lading when signing for the shipment. Next, remove the Vessel Code and bears the ASME stamp. H models bear
heater from the shipping packaging. Report any damage the "H" stamp. WH models bear the "HLW" stamp. The
to the carrier immediately. heater also complies with the latest edition of ASHRAE
90.1 Standard.
On occasion, items are shipped loose. Be sure that you
receive the correct number of packages as indicated on A  WARNING: Altering any Raypak pressure vessel
the Bill of Lading. by installing replacement heat exchangers, tube bundle
headers, or any ASME parts not manufactured and/or
Claims for shortages and damages must be filed with the approved by Raypak will instantly void the ASME and
carrier by consignee. Permission to return goods must CSA ratings of the vessel and any Raypak warranty
be received from the factory prior to shipping. Goods on the vessel. Altering the ASME or CSA ratings of the
returned to the factory without an authorized Returned vessel also violates national, state, and local approval
Goods Receipt number will not be accepted. All returned codes.
goods are subject to a restocking charge.
When ordering parts, you must specify the model and Installations at Elevation
serial number of the heater. When ordering under warranty Rated inputs are suitable for up to 2000 ft (610 m) elevation
conditions, you must also specify the date of installation. without de-rate. Consult the Factory for installations at any
Purchased parts are subject to replacement only under the altitude in excess of 2000 ft (610 m).
manufacturer’s warranty. Debits for defective replacement
parts will not be accepted. Parts will be replaced in kind
only per Raypak’s standard warranties.

5
Component Locations

Figure 1. Component Locations — General

Figure 2. Component Locations — Left Side

CONTROLLER
(OPTIONAL ON HD401)

(BEHIND CONTROLLER)

CONTROLS TRAY

Figure 3. Component Locations — Front (Panels removed for clarity)

6
General Information
Model Vent Size (in.)
Quantity of Burners
No. Flue Intake
HD101 2 4
HD151 3 4
HD201 4 5
4
HD251 5 5
HD301 6 5
HD401 8 6

Table A. Basic Data

Figure 4. Air Shutter Adjustment

Figure 5. Gas Valves

7
3. GENERAL SAFETY Time/Temperature Relationships
To meet commercial hot water use needs, the high limit in Scalds
safety control on this water heater will shut off the main gas The following chart details the relationship of water
valve before the outlet temperature reaches 210°F (99°C). temperature and time with regard to scald injury and
However, water temperatures over 125°F (52°C) can may be used as a guide in determining the safest water
cause instant severe burns or death from scalds. When temperature for your applications.
supplying general purpose hot water, the recommended
initial setting for the temperature control is 125°F (52°C). Water Temp. Time to Produce Serious Burns
Safety and energy conservation are factors to be 120°F (49°C) More than 5 minutes
considered when setting the water temperature on the 125°F (52°C) 1-1/2 to 2 minutes
thermostat. The most energy-efficient operation will result 130°F (54°C) About 30 seconds
when the temperature setting is the lowest that satisfies
135°F (57°C) About 10 seconds
the needs of the application.
140°F (60°C) Less than 5 seconds
Water temperature over 125°F (52°C) can cause instant
145°F (63°C) Less than 3 seconds
severe burns or death from scalds. Children, disabled and
elderly are at highest risk of being scalded. 150°F (66°C) About 1-1/2 seconds

• Feel water before bathing or showering. 155°F (68°C) About 1 second

• Temperature limiting valves are available. Table courtesy of The Shriners Burn Institute
Table B. Time to Produce Serious Burn
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a thermostatically Raypak offers several optional temperature controllers for
controlled mixing valve for reducing point of use water regulation of the water temperature in the heater. Type H
temperature is recommended to reduce the risk of scald models 101 through 301 are equipped as standard with an
injury. Contact a licensed plumber or the local plumbing
onboard operating controller to provide reset of the water
authority for further information.
temperature based on outdoor air temperature. To comply
with safety regulations, the temperature controller will be
Maximum water temperatures occur just after the heater’s
set at the lowest setting when shipped from the factory.
burner has shut off. To determine the water temperature
being delivered, turn on a hot water faucet and place To adjust the water temperature, insert a small straight
a thermometer in the hot water stream and read the screwdriver into the adjustment wheel on the front of
thermometer. temperature control and turn the wheel to the desired
setting (See Figure 6).

ADJUSTMENT
WHEEL

Water temperature over 125°F

(52°C) can cause instant severe
burns or death from scalds. Figure 6. Temperature Controller

Children, disabled, and elderly are CAUTION: Hotter water increases the risk of
at highest risk of being scalded. A 
scalding! There is a hot water scald potential if the
See instruction manual before thermostat is set too high.
setting temperature at water heater
Feel water before bathing or show-
ering.

Temperature limiting valves are

available, see manual.

8
4. INSTALLATION A  WARNING: This product must be installed by a
licensed plumber or gas fitter when installed within the
Commonweatlh of Massachusetts.
Installation Codes
Installations must follow these codes:
Clearances
• Local, state, provincial, and national codes, laws,
regulations and ordinances. Indoor/Closet Installations
Minimum Installed Combustible Clearance
• National Fuel Gas Code, ANSI Z223.1- latest edition Heater Side
in. (cm)
(NFGC).
Front 24 (61)
• National Electrical Code, ANSI/NFPA 70 - latest
Rear 2 (5)
edition (NEC).
Floor* 0
• Standard for Controls and Safety Devices for
Top 24 (61)
Automatically Fired Heaters, ANSI/ASME CSD-1,
when required (CSD-1). Left** 12 (30.5)
Right** 6 (15)
• For Canada only: CAN/CGA B149 Installation Code
(B149) and C.S.A. C22. 1 C.E.C. Part 1 (C22. 1). Water Side 24 (61)

*DO NOT install on carpeting.

Equipment Base **When water connections are on other side.

Table C. Combustible Clearances — Indoor/Closet
The heater should be mounted on a level, structurally Installations
sound surface. The heater is approved for installation on
a combustible surface but must NEVER be installed on A  CAUTION: Service clearances less than the
carpeting. Gas-fueled equipment installed in enclosed minimums may require removal of the heater to service
parking garages must be located at least 18 in. (45.7 cm) either the heat exchanger or the burners.
above the floor.
The heater must be installed in a manner that will enable
CAUTION: The heater should be located in an area
A  the heater to be serviced without removing any structure
where water leakage will not result in damage to the area around the heater.
adjacent to the appliance or to the structure. When such
locations cannot be avoided, it is recommended that
a suitable catch pan, adequately drained, be installed
Outdoor Installations
under the appliance. The pan must not restrict air flow. These heaters are design-certified for outdoor installation.
Heaters must not be installed under an overhang unless
In addition, the heater shall be installed such that the gas clearances are in accordance with local installation codes
ignition system components are protected from water and the requirements of the gas supplier. Three sides must
(dripping, spraying, rain, etc.) during appliance operation be open in the area under the overhang (see Figure 8).
or service (circulator replacement, control replacement, Roof water drainage must be diverted away from heaters
etc.). installed under overhangs.

(WATER SIDE)
24" (61 cm) 6" (15.2 cm)

24" (61 cm)

12"
(30.5 cm)

24" (61 cm)

F10069

Figure 7. Minimum Installed Service Clearances — Indoor/Closet Installations

9
These clearances are required when the outdoor vent cap Minimum Installed Service Clearance
is used. If installing the heater outdoors with a vent stack, Heater Side
in. (cm)
the indoor clearances may be utilized.
Front 24 (61.0)
The combustion air intake hood MUST be used for outdoor Rear 12 (30.5)
installations. The hood is shipped loose and installed on
Top Unobstructed
the side of the heater over the filter box at the job site.
Other Side 36 (91.4)
Water Side 36 (91.4)

Table D. Service Clearances — Outdoor Installations

24" (61 cm) 24" (61 cm)

MIN. 36" (91.4 cm) 36" (91.4 cm) MIN.

12"
24"
(30.5 cm)
(61 cm)

F10070

Figure 8. Minimum Installed Service Clearance — Outdoor Installations with Vent Stack

of the same cross-sectional area as the free area of the

Conventional Combustion Air Supply openings to which they connect.
1. Two permanent openings, one commencing within
U.S. Installations 12 in. (30.5 cm) of the top, and one commencing
within 12 in. (30.5 cm) of the bottom, of the enclosure
All Air from Inside the Building
shall be provided. The openings shall communicate
The confined space shall be provided with two permanent directly, or by ducts, with the outdoors or spaces
openings communicating directly with an additional (crawl or attic) that freely communicate with the
room(s) of sufficient volume so that the combined volume outdoors.
of all spaces meets the criteria for an unconfined space.
a. Where directly communicating with the outdoors
The total input of all gas utilization equipment installed in
or where communicating to the outdoors through
the combined space shall be considered in making this
vertical ducts, each opening shall have a
determination. Each opening shall have a minimum free
minimum free area of 1 in.² per 4000 BTUH (5.5
area of 1 in.² per 1,000 BTUH (22 cm² per kW) of the total
cm² per kW) of total input rating of all equipment
input rating of all gas utilization equipment in the confined
in the enclosure.
space, but not less than 100 in.² (645 cm²). One opening
shall commence within 6-3/4 in. (17.1 cm) of the top, and b. Where communicating with the outdoors through
one opening shall commence within 6-3/4 in. (17.1 cm) horizontal ducts, each opening shall have a
of the bottom, of the enclosure. The minimum dimension minimum free area of 1 in.² per 2000 BTUH (11
of air openings shall be not less than 3 in. (7.6 cm) in any cm² per kW) of total input rating of all equipment
direction. in the enclosure.

All Air from Outdoors 2. One permanent opening, commencing within 12

in. (30.5 cm) of the top of the enclosure, shall be
The confined space shall communicate with the outdoors permitted where the equipment has clearances of
in accordance with methods 1 or 2 below. The minimum at least 1 in. (2.5 cm) from the sides and back and
dimension of air openings shall not be less than 3 in. (7.6 6 in. (15.2 cm) from the front of the appliance. The
cm) in any direction. Where ducts are used, they shall be opening shall directly communicate with the outdoors

10
 or shall communicate through a vertical or horizontal more than 18 in. (45.7 cm) nor less than 6 in. (15.2
duct to the outdoors or spaces (crawl or attic) that cm) above the floor level. The duct can also “Goose
freely communicate with the outdoors, and shall Neck” through the roof. The duct is preferred to be
have a minimum free area of: straight down 18" (45.7 cm) from floor, but do not
place near piping.
a. 1 in.² per 3000 BTUH (7 cm² per kW) of the
total input rating of all equipment located in the 4. Refer to the latest version of the B149 for additional
enclosure, and information.
b. \Not less than the sum of the areas of all vent
connectors in the confined space. Combustion and Ventilation Air
A  WARNING: Do not use one permanent opening Contamination of Combustion Air
method if the equipment room is under negative
pressure conditions or the equipment is common vented All heaters experience some condensation during start-up.
with other gas-fired appliances. The condensate from flue gas is slightly acidic. In most
cases the pH level is not harmful to vents or drains. When
combustion air is contaminated by vapors from products
Installations in Canada in areas listed below, the acidic levels in the condensate
A  CAUTION: All combustion air must be drawn from increase. Higher acidic levels attack many materials,
the air outside of the building; the mechanical equipment including stainless steel commonly used in high efficiency
room must communicate directly with the outdoors. systems.
The heater can use special corrosion-resistant nonmetallic
1. Ventilation of the space occupied by the heater shall
intake vent material. You may, however, choose to use
be provided by an opening(s) for ventilation air at the
outside combustion air for one or more of these reasons:
highest practical point communicating with outdoors.
The total cross-sectional area of such an opening(s) • installation is in an area containing contaminants
shall be at least 10% of the area required in (2) and listed below which will induce acidic condensation.
(3), but in no case shall the cross-sectional area be • you want to reduce infiltration into your building
less than 10 in.² (6500 mm²). through openings around windows and doors.
2. For heaters using a barometric damper in the vent • you are using AL29-4C stainless steel vent pipe,
system, and when air supply is provided by natural which is more corrosion-resistant than standard
air flow from the outdoors for natural draft, partial metallic vent pipe. In extremely contaminated areas,
fan assisted, fan-assisted or power draft-assisted this may also experience deterioration.
burners, there shall be a permanent air supply
opening(s) having a cross section area of not less Products causing contaminated combustion air:
than 1 in.² per 7000 BTUH (310 mm² per kW) up to • spray cans containing chloro/fluorocarbons
and including 1 million BTUH, plus 1 in.² per 14000
• permanent wave solutions
BTUH (155 mm² per kW) in excess of 1 million BTUH.
This opening(s) shall be either located at or ducted • chlorinated waxes/cleaners
to a point not more than 18 in. (45.7 cm) nor less • chlorine-based swimming pool chemicals
than 6 in. (15.2 cm) above the floor level. The duct
• calcium chloride used for thawing
can also “Goose Neck” through the roof. The duct
is preferred straight down 18" (45.7 cm) from floor, • sodium chloride used for water softening
but do not place near piping. This air supply opening • refrigerant leaks
requirement shall be in addition to the air opening for
ventilation air required in (1). • paint or varnish removers

3. For heaters not using a barometric damper in the • hydrochloric acid/muriatic acid
vent system, and when air supply is provided by • cements and glues
natural air flow from outdoors for a power burner and
• antistatic fabric softeners used in clothes dryers
there is no draft regulator, drafthood or similar flue
gas dilution device installed in the same space, in • chloride-type bleaches, detergents, and cleaning
addition to the opening for ventilation air required in solvents found in household laundry rooms
(1), there shall be a permanent air supply opening(s) • adhesives used to fasten building products and other
having a total cross-sectional area of not less than similar products.
1 in.² for each 30,000 BTUH (70 mm² per kW) of
Areas causing contaminated combustion air:
total rated input of the burner(s), and the location of
the opening(s) shall not interfere with the intended • dry cleaning/laundry areas and establishments
purpose of the opening(s) for ventilation air referred • metal fabrication plants
to (1). This opening(s) can be ducted to a point not
11
• beauty shops
Indoor Units
• refrigeration repair shops
The heater must be supplied with sufficient quantities of
• photo processing plants non-contaminated air to support proper combustion and
• auto body shops equipment ventilation. Combustion air can be supplied
via conventional means where combustion air is drawn
• plastic manufacturing plants
from the area immediately surrounding the heater, or via
• furniture refinishing areas and establishments duct, where combustion air is drawn directly from outside.
• new building construction All installations must comply with the requirements of the
NFGC (U.S.) and B149 (Canada), and all local codes.
• remodeling areas.
A  CAUTION: Combustion air must not be contaminated
Check for areas and products as listed above before by corrosive chemical fumes which can damage the
installing heater. If found: heater and void the warranty. (See "Inside Combustion
• remove products permanently, OR Air Contamination" on page 11.)

• provide outdoor combustion air.

Water Piping
Ducted Combustion Air
If outside air is drawn through the intake pipe directly to the General
unit for combustion: The heater should be located so that any water leaks will
1. Install combustion air duct in accordance with the not cause damage to the adjacent area or structures.
venting section of this manual, see 24 to 27. A  CAUTION: This heater requires forced water
2. Provide adequate ventilation of the space occupied circulation when the burner is operating. See Table E
and Table F for minimum and maximum flow rates and
by the heater(s) by an opening(s) for ventilation air
water pump selection. The pump must be interlocked
at the highest practical point communicating with the with the heater to prevent heater operation without water
outdoors. The total cross-sectional area shall be at circulation.
least 1 in.² of free area per 20,000 BTUH (111 mm²
per kW) of total input rating of all equipment in the
room when the opening is communicating directly Reversing Water Connections
with the outdoors or through vertical duct(s). The Follow these instructions to change the water connections
total cross-sectional area shall be at least 1 in.² of from the left-hand side (standard) to the right-hand side.
free area per 10,000 BTUH (222 mm² per kW) of total This is an ASME-Certified pressure vessel. It is the
input rating of all equipment in the room when the installer’s responsibility to ensure that the pressure vessel
opening is communicating with the outdoors through is properly sealed after making these changes.
horizontal duct(s). This opening must meet the
location requirements of the National Fuel Gas Code. 1. Disconnect all electrical power from the heater (if
applicable).
3. In cold climates, and to mitigate potential freeze-
up, Raypak highly recommends the installation of a 2. Label all electrical connections and conduit lines.
motorized sealed damper to prevent the circulation This may include the flow switch, low water cut-off
of cold air through the heater during non-operating probe and/or pump.
hours. 3. Disconnect or isolate the main gas pipe from the
4. If the combustion air ducting is sealed (RTV heater (if applicable).
recommended) and sealed-joint flue material is 4. Remove both in/out and return header access panels
used, the resulting installation will meet direct-vent by removing all sheet metal screws.
requirements. 5. Remove all plumbing fittings to the header. This will
include both inlet and outlet water pipe unions and
Combustion Air Filter the pressure relief valve and drain piping.
This heater is supplied with an integral combustion air filter. 6. Remove limits, control bulbs and/or sensors.
This filter will reduce the amount of particulates passed
through the combustion system and heat exchanger but 7. Remove the six flange nuts and the in/out header
will not protect against chemical inside air contamination from the left-hand side.
(See page 11). The filter must be checked periodically 8. Remove the six flange nuts and the return header
to verify that adequate combustion air is being supplied from the right-hand side.
to the heater. See "MAINTENANCE" on page 43 for 9. Remove the header stud bolts from each tube sheet.
information on checking the filter and establishing service
intervals. 10. Reverse the headers and stud bolts to the new
location.
12
11. Install NEW red beveled O-rings flush against both 1. Connect fill water supply. Fill heater with water (be
tube sheets with the bevel facing outward. sure bleed valve is open). When water flows from
12. Push the header firmly against the O-rings. Install bleed valve, shut off water. Close bleed valve.
and tighten the flange nuts onto the stud bolts until Carefully fill the rest of the system, being sure to
finger tight. eliminate any entrapped air by using high point vents.
Close feed valve. Test at standard operating pressure
13. Slowly tighten the flange nuts, starting from the center for at least 24 hours.
nut (number 1) in Figure 9 and working sequentially
around the header as indicated. Torque all nuts to 25 2. Make sure constant gauge pressure has been
ft/lb. DO NOT OVER-TIGHTEN. maintained throughout test.

14. Re-route the capillary(s), wiring, etc., to the new 3. Check for leaks. Repair if found.
location, adding thermal paste and shim to the
capillary well.
Low Temperature System
Heater requires minimum inlet temperature of 105°F.
Consult the following sections for piping details.
Temperature & Pressure Gauge
The temperature and pressure gauge is shipped loose for
field installation.

Hydronic Heating
System Design
Hot water heating systems all have unique levels of
operating diversity. Raypak equipment design utilizes as
little water mass as possible to ensure maximum operating
efficiency. Primary / Secondary piping arrangement is the
method recommended and the only method supported
Figure 9. Torque Sequence by Raypak for installation of Raypak heating equipment.
Proper system design should always include system
flow in excess of the connected boiler flow for proper
Relief Valve Piping operation (Boiler Flow + 15% = Min. System Flow). When
A  WARNING: Pressure relief valve discharge piping appropriate, a Buffer/De-coupler Tank can be used where
must be piped near the floor and close to a drain to system flow may be reduced below the connected boiler
eliminate the potential of severe burns. Do not pipe flow. Failure to design for adequate system flow (i.e.
to any area where freezing could occur. Refer to local bypasses, 3-way control valves, flow limiting balance
codes. devices, buffer tanks, etc.) will result in boiler short-cycling
and poor system performance. Always contact your local
Raypak representative for system design assistance to
Hydrostatic Test avoid these issues.
Unlike many other types of heaters, Raypak heaters do not
require hydrostatic testing prior to being placed in operation. Pump Selection
The heat exchanger has already been factory-tested and is In order to ensure proper performance of your boiler
rated for 160 psi maximum operating pressure. However, system, you must install a properly-sized pump. Raypak
Raypak does recommend hydrostatically testing the recommends using a 20°F (11°C) ∆T as design ∆T. (∆T
piping connections to the heater and the rest of the system is the temperature difference between the inlet and outlet
prior to operation. This is particularly true for hydronic water when the heater is firing at full rate). If a ∆T other
systems using expensive glycol-based antifreeze. Raypak than 20°F (11°C) is necessary, see Table E for flow rate
recommends conducting the hydrostatic test before requirements.
connecting gas piping or electrical supply.
Leaks must be repaired at once to prevent damage
to the heater. NEVER use petroleum-based stop-leak
compounds.

13
 ∆T 10°F (5.5°C) ∆T 20°F (11°C) ∆T 30°F (17°C) Min. Flow Max. Flow
Model Input Output
No. MBTUH MBTUH gpm ∆P gpm ∆P gpm ∆P gpm ∆P ∆T gpm ∆P ∆T
(lpm) (ft) (lpm) (ft) (lpm) (ft) (lpm) (ft) °F (°C) (lpm) (ft) °F (°C)
HD101 100 85 17 (64) 1.3 13 (49) 0.7 14 (8) 44 (167) 8.8 4 (2)
HD151 150 128 26 (98) 3.0 13 (49) 0.7 13 (49) 0.7 20 (11) 44 (167) 8.8 6 (3)
HD201 199 169 34 (129) 5.3 17 (64) 1.3 13 (49) 3.4 27 (15) 44 (167) 8.9 8 (4)
HD251 250 213 44 (167) 9.2 21 (79) 2.1 14 (53) 1.0 13 (49) 0.7 34 (19) 44 (167) 9.2 10 (5.5)
HD301 299 254 25 (95) 3.1 17 (64) 1.4 13 (49) 0.8 40 (22) 44 (167) 9.4 12 (7)
HD401 399 335 34 (129) 5.6 22 (83) 2.5 17 (64) 1.4 40 (22) 44 (167) 9.8 15 (8)

*Flow switch will not activate at less than 12 gpm (45 lpm).
NOTE: Basis for minimum flow — 13 gpm (49 lpm) or 40°F (22°C) ∆T maximum flow — gpm, except for header.
Table E. Flow and Pressure Drop, H Models

System flow must always exceed boiler flow for proper

Pressure Drop in Feet of Head Feedwater
operation. Raypak strongly recommends a minimum
Regulator system flow of 115% of the boiler flow.
Raypak recommends that a feedwater regulator be
installed and set at 12 psi minimum pressure at the highest
Air-Separation/Expansion Tank
point of system. Install a check valve or back flow device
upstream of the regulator, with a manual shut off valve as All boilers should be equipped with a properly sized
required by local codes. expansion tank and air separator fitting as shown in the
piping diagrams (Figure 10 through Figure 13).
Piping—Heating Boilers Three-Way Valves
All high points should be vented. Purge valves and Valves designed to blend water temperatures or reduce
a bypass valve should be installed. A boiler installed water circulation through the boiler should not be used.
above radiation level must be provided with a low water Raypak boilers are high recovery low mass boilers not
cut-off device. The boiler, when used in connection with subject to thermal shock. Raypak offers a full line of
a refrigeration system, must be installed so the chilled electric sequencers that produce direct reset of boiler
medium is piped in parallel with the boiler with appropriate water temperature. Refer to the Controls Section in our
valves to prevent the chilled medium from entering the Complete Catalog.
boiler.
The boiler piping system of a hot water heating boiler Domestic Hot Water Piping
connected to heating coils located in air handling units
where they may be exposed to circulating refrigerated When designing the water piping system for domestic
air, must be equipped with flow control valves or other water applications, water hardness should be considered.
automatic means to prevent gravity circulation of the boiler Table F indicates the suggested flow rates for soft, medium
water during the cooling cycle. It is highly recommended and hard water. Hardness is specified as grains per gallon.
that the piping be insulated.

MAX 4 SYSTEM PIPE

DIAMETERS NOT TO
EXCEED 12" (30.5 cm)

Figure 10. Single Boiler — Primary/Secondary Piping

14
 5 FT MAX
(1.5 m)

MAXIMUM 4 TIMES THE

SYSTEM PIPE DIAMETER NOT
TO EXCEED 12" (30.5 cm)

Figure 11. Single Boiler — Low-Temperature Application (Heat Pump) Primary/Secondary Piping

5 FT MAX
(1.5 m)

MAXIMUM 4 TIMES
THE SYSTEM PIPE
DIAMETER NOT TO
EXCEED 12" (30.5 cm)

Figure 12. Dual Boiler—Primary/Secondary Piping

15
 TANKSTAT OR
TANK SENSOR
WHEN EQUIPPED

Figure 13. Single Heater — Domestic Hot Water with One Storage Tank

Soft (0–4 grains per gallon) Medium (5–15 grains per gallon) Hard (16–25* grains per gallon)
Model Input Output
No. MBTUH MBTUH ∆T gpm ∆T gpm ∆T gpm
∆P MTS SHL ∆P MTS SHL ∆P MTS SHL
ºF (ºC) (lpm) ºF (ºC) (lpm) ºF (ºC) (lpm)
HD101 100 85 9 (5) 1.8 3.8 7 (4) 3.0 6.3 4 (2) 9.2 18.0
HD151 150 128 13 (7) 1.8 3.8 10 (5.5) 3.1 6.3 6 (3) 9.2 18.1
HD201 199 169 17 (9) 20 1.9 3.9 13 (7) 26 3.2 6.4 8 (4) 45 9.4 18.2
1-1/2 1-1/2 1-1/2
HD251 250 213 21 (12) (76) 1.9 3.9 16 (9) (98) 3.2 6.5 9 (5) (170) 9.6 18.5
HD301 299 254 25 (14) 1.9 3.9 20 (11) 3.2 6.5 11 (6) 9.8 18.7
HD401 399 339 34 (19) 2.0 4.0 26 (14) 3.3 6.6 15 (8) 10.3 19.1

∆T = Temperature rise, °F (°C).

∆P = Pressure drop through heat exchanger, ft.
SHL = System head loss, ft. (System head loss is based on the heater and tank placed no more than 5 feet apart and 50 feet equivalent length of
tubing and fittings.)
gpm = Gallons per minute, flow rate.
MTS = Minimum tubing size.
*With Hard Water (16-25 grains per gallon), the operating control must be set no higher than 130°F (54°C) for scale-free operation. For operating
temperatures above 130°F (54°C), a water softener must be utilized.
Table F. Flow Requirements, WH Models

16
Gas Supply Gas Supply Pressure
A  DANGER: Make sure the gas on which the heater A minimum of 4 in. WC and a maximum of 10.5 in. WC
will operate is the same type as specified on the heater’s upstream gas pressure is required under load and no load
rating plate. conditions for natural gas. A minimum of 11 in. WC and a
maximum of 13 in. WC is required for propane gas. The
Gas piping must have a sediment trap ahead of the heater gas pressure regulator supplied on the heater is for low
gas controls, and a manual shutoff valve located outside pressure service. If upstream pressure exceeds 14 in. WC,
the heater jacket. A pounds-to-inches regulator must be an intermediate gas pressure regulator, of the lockup type,
installed to reduce the natural gas supply pressure to must be installed.
under 10.5 in. WC (13.0 in. WC for propane gas). The
regulator should be placed a minimum distance of 10 times When connecting additional gas utilization equipment to
the pipe diameter upstream of the heater gas controls. All the gas piping system, the existing piping must be checked
gas piping must be tested after installation in accordance to determine if it has adequate capacity.
with local codes. The heater and its gas connection must Gas Type
Firing
be leak-tested before placing it in operation. Gas Valve LP/
Stage Natural
Propane
Gas Supply Connection Invensys 3.4" WC
CAUTION: The heater and its manual shutoff valve
A  Hi-Fire
must be disconnected from the gas supply during +/- 0.2”WC Honeywell or
3.1" WC 9.6" WC
any pressure testing of the gas supply system at test White-Rodgers
pressures in excess of 1/2 psi (3.45 kPa). The heater Invensys 1.1" WC
must be isolated from the gas supply piping system by Lo-Fire
closing the manual shutoff valve during any pressure +/- 0.1”WC Honeywell or
testing of the gas supply piping system at test pressures 1.2" WC 3.6" WC
White-Rodgers
equal to or greater than 1/2 psi. Relieve test pressure in
the gas supply line before reconnecting the heater and
Table G. Pressure at Gas Valve Outlet Tap
its manual shutoff valve to the gas supply line. FAILURE
TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS
VALVES. Over-pressurized gas valves are not covered Gas Pressure Regulator
by warranty. The heater and its gas connections shall
be leak tested before placing the appliance in operation. The gas valve pressure regulator(s) on the heater are
Use soapy water for leak test: DO NOT use open flame. nominally preset at 3 in. WC for natural gas, and 10.0 in.
WC for propane gas manifold pressure. The pressure at
A  CAUTION: Do not use Teflon tape on gas line pipe the gas valve outlet tap, measured with a manometer,
thread. A pipe compound rated for use with gas systems while in operation should be as indicated in Table G. If
is recommended. Apply sparingly only on male pipe an adjustment is needed, turn the adjustment screw
ends. clockwise to increase pressure or counter-clockwise to
decrease pressure.
A  CAUTION: Support gas supply piping with hangers,
not by the heater or its accessories. Ensure the gas
piping is protected from physical damage and freezing
where required.

HEATER
MANUAL GAS INLET JACKET
SHUT-OFF
VALVE GAS VALVE

3" (7.6 cm)

MIN TYPICAL
UNION

SEDIMENT
TRAP
FIELD-SUPPLIED F10060

Figure 14. Sediment Trap Orientation

17
 Maximum Equivalent Length (ft/m)
Model
Input 3/4" 1" 1-1/4" 1-1/2"
No.
(KBTUH) NAT PRO NAT PRO NAT PRO NAT PRO
HD101 100 105 (32.0) 385 (117.3) 340 (103.6)
HD151 150 50 15.2) 180 (54.9) 160 (48.8) 530 (161.5) 600 (182.9)
HD201 199 30 (9.1) 95 (29.0) 95 (29.0) 355 (108.2) 360 (109.7)
HD251 250 20 (6.1) 50 (15.2) 60 (18.3) 230 (70.1) 240 (73.2)
HD301 299 15 (4.6) 35 (10.7) 45 (13.7) 170 (51.8) 170 (51.8) 550 (167.6) 360 (109.7)
HD401 399 5 (1.5) 20 (6.1) 25 (7.6) 80 (24.4) 100 (30.5) 365 (111.3) 210 (64.0)

Natural gas – 1,000 BTUH per ft³, .60 specific gravity at 0.5 in. WC pressure drop
Propane gas – 2,500 BTUH per ft³, 1.50 specific gravity at 0.5 in. WC pressure drop
Elbow = 10 ft effective length, max 4 elbows
Table H. Gas Supply Piping

If any of the original wire as supplied with the heater must

Electrical Power Connections be replaced, it must be replaced with 105°C wire or its
Installations must follow these codes: equivalent.
• National Electrical Code and any other national, Check the Power Source
state, provincial or local codes or regulations having
jurisdiction A  WARNING: Using a volt-ohm meter (VOM), check the
following voltages at the terminal block inside the unit.
• Safety wiring must be N.E.C. Class 1 Make sure proper polarity is followed and house ground
• Heater must be electrically grounded as required by is proven.
N.E.C.
AC = 108 Volts AC Minimum, 132 Volts AC MAX
• In Canada, C22.1
AB = 108 Volts AC Minimum, 132 Volts AC MAX
The heater is wired for 120 VAC, less than 12 AMPS. The
BC = < 1 Volt AC
voltage is indicated on the tie-in leads. Consult the wiring
diagram shipped with the heater in the instruction packet.
BLACK
The remote tank control stat, thermostat, or electronic
CIRCUIT
BREAKER

heater control as applicable, may be connected to stage WHITE

VOLT-OHM
METER

selector terminal (see wiring diagram). 24 Volts are

GREEN
supplied to this connection through the heater transformer.
DO NOT attach line voltage to the stage connections.
GROUND

Before starting the heater check to ensure proper voltage

to the heater and pump.
A B C
Install a separate disconnect means for each load.
WARNING: Connecting line voltage to the stage Figure 15. Check Power Source
A 
connection terminal block will cause damage to the unit
that is not covered by warranty. Making the Electrical Connections
Refer to Figure 15 and the Wiring Diagram.
Use appropriate-sized wire as defined by NEC, CSA
and/or local code. All primary wiring should be 125% of 1. Verify circuit breaker is properly sized by referring
minimum rating. to heater rating plate. A dedicated circuit breaker
should be provided.
It is strongly recommended that all individually-powered
control modules and the heater should be supplied from 2. Turn off all power to the heater. Verify that power
the same power source. has been turned off by testing with a volt-ohm meter
prior to working with any electrical connections or
Surge Protection components.
Microprocessor-based and solid state controls are 3. Observe proper wire colors while making electrical
vulnerable to damage from voltage and amperage connections. Many electronic controls are polarity
fluctuations in the power supply. All sensitive control sensitive. Components damaged by improper
components should be protected by a suitable commercial- electrical installation are not covered by warranty.
grade surge protection device.

18
4. Provide an external surge suppressor capable of For operation with a Temp-Tracker controller, refer to the
maintaining system integrity. Temp-Tracker Installation and Operating Instructions,
5. Provide overload protection and a disconnect means Raypak P/N 241177.
for equipment serviceability as required by local and Consult the wiring diagram shipped with the heater in the
state code. instruction packet. The Stage 1 connections are for the
6. Install heater controls, thermostats, or building remote tank control through the heaters 24 volt transformer.
management systems in accordance with the DO NOT attach line voltage to the Stage 1 connection.
applicable manufacturer’s instructions. Before starting heater, check to ensure proper voltage to
heater and pump.
7. Conduit should not be used as the ground. There SINGLE
must be a solidly wired ground. STAGE
TANKSTAT
NOTE: A grounding electrode conductor shall be
used to connect the equipment grounding conductors,
the equipment enclosures, and the grounded service
conductor to the grounding electrode.

Electrical Connections — Domestic Hot STAGE 1

CONNECTION
Water
A  DANGER—SHOCK HAZARD: Make sure electrical
power to the heater is disconnected to avoid potential
serious injury or damage to components. ATTACH STAGE 1 CONNECTIONS ON HEATER
TO THE SINGLE STAGE TANKSTAT AS SHOWN
IN THE DIAGRAM ABOVE.
A CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause Figure 17. Single Stage Tankstat
improper and dangerous operation. Verify proper
operation after servicing. 2-STAGE
TANKSTAT

NOTE: Minimum 18 AWG, 105°C, stranded wire must

be used for all low voltage (less than 30 volts) external
connections to the unit. Solid conductors should not
be used because they can cause excessive tension on
contact points. Install conduit as appropriate. All high
voltage wires must be the same size (105°C, stranded
STAGE 2 CONNECTION OR
wire) as the ones on the unit or larger. STAGE 1 STAGE 1 CONNECTION
CONNECTION OF HEATER 2
Installer action is required to electrically enable your Hi Delta
heater to operate after making the power connections. You
must use Terminal Block connections 1 through 4 for the ATTACH STAGE 1 CONNECTIONS ON HEATER
temperature controller, as shown in Figure 16. This will TO STAGE 1 CONNECTION ON TANKSTAT.
be done based on the controller option selected with your ATTACH STAGE 2 CONNECTIONS OR
STAGE 1 CONNECTION OF HEATER 2
heater order. TO STAGE 2 CONNECTION ON TANKSTAT
AS SHOWN IN THE DIAGRAM.

Figure 18. 2-Stage Tankstat

1 2 3 4 5 6 7 8 9 10 11 12
STAGE 1 STAGE 2 ENABLE / INTERLOCK / ALARM 24V 24VR Heater must be electrically grounded in accordance with
DISABLE OR
SEQUENCER
LOUVER SW DRY
CONTACTS
CWS / CWR
FAN / DAMPER
NEC and C22.1(in Canada).
(PILOT DUTY)
JUMPERED
WHEN NOT USED
(OPTIONAL) JUMPERED
WHEN NOT USED
(OPTIONAL) NOTES:
1. Field installed ground to inside of junction box.
CONDUCTORS ONLY

2. If any of the original wire as supplied with the heater

USE COPPER

must be replaced, it must be replaced with 105°C

wire or its equivalent.
P/N 901935 REV 1

1 2 3 4 5 6
HOT COM G HOT COM HOT
POWER IN SAFETY VALVE PUMP

Figure 16. Terminal Block Connections

19
Venting Determination of Appliance Category
for Venting Purposes and Venting
General Arrangements
A  CAUTION: Proper installation of flue venting is
A  WARNING: Contact the manufacturer of the vent
critical for the safe and efficient operation of the heater.
material if there is any question about the appliance
categorization and suitability of a vent material for
Definition of Appliance Categories application on a Category III or IV vent system. Using
Heaters are divided into four categories based on the improper venting materials can result in personal injury,
death or property damage.
pressure produced in the exhaust and the likelihood of
condensate production in the vent.
Category I. A heater which operates with a non-positive Barometric Damper
vent static pressure and with a vent gas temperature that A barometric damper may be required when vent heights
avoids excessive condensate production in the vent. exceed 25 ft (7.6 m) or when the draft is greater than
Category II. A heater which operates with a non-positive -0.08 in. WC. In these installations, a barometric damper
vent static pressure and with a vent gas temperature that (single-acting) is required.
may cause excessive condensate production in the vent. The damper should be installed 5 ft (1.5 m) higher than the
Category III. A heater which operates with a positive vent discharge of the unit and no closer than 18 in. (45.7 cm)
pressure and with a vent gas temperature that avoids from a combustible ceiling. The damper can be installed
excessive condensate production in the vent. in horizontal or vertical runs of vent pipe as necessary.
Installation in a bull-head tee is acceptable as shown in
Category IV. A heater which operates with a positive vent the NFGC.
pressure and with a vent gas temperature that may cause
excessive condensate production in the vent. The weights on the damper should be adjusted per the
damper manufacturer’s instructions for proper operation,
See Table I for appliance category requirements for the to maintain –0.01 to –0.08 in. WC, 12 in. (30.5 cm) from
Hi Delta. the heater outlet, at all firing conditions.
NOTE: For additional information on appliance
categorization, see appropriate ANSI Z21 Standard Support of Vent Stack
and the NFGC (U.S.), or B149 (Canada), or applicable
The weight of the vent stack or chimney must not rest on
provisions of local building codes.
the heater vent connection. Support must be provided
in compliance with applicable codes. The vent should
also be supported to maintain proper clearances from
combustible materials.
Use insulated vent pipe spacers where the vent passes
through combustible roofs and walls.

Combustion Combustion Air

Exhaust Configuration Venting Category Certified Appliance Material
Air Supply Inlet Material
Vertical I
From Inside Type B or any Category I Venting System*
Natural Draft Venting Fan-Assisted
Building (Non-
Direct Venting) Horizontal
III Stainless Steel (Gas Tight)
Thru-wall Venting
From Outside Vertical I Galvanized Steel
Type B or any Category I Venting System*
Building Venting Fan-Assisted PVC
(Direct Horizontal ABS
Venting) III Stainless Steel (Gas Tight) CPVC
Thru-wall Venting

*As defined in the latest edition of the NFGC, or in Canada, the B149.
Table I. Venting Category Requirements

20
 Figure 19. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

1 2
U.S. Installations Canadian Installations
Clearance above grade, veranda, porch,
A 1 ft (30 cm) 1 ft (30 cm)
deck, or balcony
4 ft (1.2m) below or to side
Clearance to window or door that may be
B of opening; 1 foot (30 cm) 3 ft (91 cm)
opened
above opening
C Clearance to permanently closed window * *
Vertical clearance to ventilated soffit located
above the terminal within a horizontal dis-
D 5 ft (1.5m) *
tance of 2 ft (61cm) from the centerline of the
terminal
E Clearance to unventilated soffit * *
F Clearance to outside corner * *
G Clearance to inside corner 6 ft (1.83m) *
3 ft (91 cm) within a height
Clearance to each side of center line ex-
H * 15 ft above the me-
tended above meter/regulator assembly
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft (1.83m)
Clearance to non-mechanical air supply inlet 4 ft (1.2m) below or to side
J to building or the combustion air inlet to any of opening; 1 ft (30 cm) 3 ft (91 cm)
other appliance above opening
3 ft (91 cm) above if within
K Clearance to mechanical air supply inlet 6 ft (1.83m)
10 ft (3m) horizontally
Clearance above paved sidewalk or paved
L 7 ft (2.13m) 7 ft (2.13m) ³
driveway located on public property
Clearance under veranda, porch, deck or
M * 12 in. (30 cm) ⁴
balcony
1
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2
In accordance with the current CAN/CSA-B149 Installation Codes
³ Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves
both dwellings
⁴ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30cm)
* Clearances in accordance with local installation codes and the requirements of the gas supplier

Table J. Vent/Air Inlet Termination Clearances

21
 b. The vent must not be less than 7 ft (2.1 m) above
Vent Terminal Location grade when located adjacent to public walkways.
NOTE: During winter months check the vent cap and c. Terminate vent at least 3 ft (0.9 m) above any
make sure no blockage occurs from build up of snow.
forced air inlet located within 10 ft (3.0 m).
1. Condensate can freeze on the vent cap. Frozen d. Vent must terminate at least 4 ft (1.2 m)
condensate on the vent cap can result in a blocked horizontally, and in no case above or below
flue condition. unless 4 ft (1.2 m) horizontal distance is
maintained, from electric meters, gas meters,
2. Give special attention to the location of the vent
regulators, and relief equipment.
termination to avoid possibility of property damage
or personal injury. e. Terminate vent at least 6 ft (1.8 m) away from
adjacent walls.
3. Gases may form a white vapor plume in winter. The
plume could obstruct a window view if the termination f. DO NOT terminate vent closer than 5 ft (1.5 m)
is installed in close proximity to windows. below roof overhang.
4. Prevailing winds, in combination with below freezing g. The vent terminal of a direct vent appliance with
temperatures, can cause freezing of condensate and an input over 50,000 BTUH per hour shall require
water/ice build-up on buildings, plants or roofs. a 12 in. (30.5 cm) vent terminal clearance.
5. The bottom of the vent terminal and the air intake h. Terminate vent at least 1 ft (30.5 cm) above
shall be located at least 12 in. (30.5 cm) above grade, including normal snow line.
grade, including normal snow line. i. Multiple direct vent installations require a 4 ft
6. Un-insulated single-wall metal vent pipe shall not (1.2 m) clearance between vent caps.
be used outdoors on cold climates for venting gas
utilization equipment. Installations in Canada
7. Through-the-wall vents for Category II and IV Refer to latest edition of CAN/CGA-B149.
appliances and non-categorized condensing A vent shall not terminate:
appliances shall not terminate over public walkways
a. Directly above a paved sidewalk or driveway
or over an area where condensate or vapor could
which is located between two single family
create a nuisance or hazard or could be detrimental
dwellings and serves both dwellings.
to the operation of regulators, relief valves, or other
equipment. Where local experience indicates that b. Less than 7 ft (2.1 m) above a paved sidewalk or
condensate is a problem with Category I and III paved driveway located on public property.
appliances, this provision shall also apply. c. Within 6 ft (1.8 m) of a mechanical air supply
8. Locate and guard vent termination to prevent inlet to any building.
accidental contact by people or pets. d. Above a meter/regulator assembly within 3 ft
9. DO NOT terminate vent in window well, stairwell, (91.4 cm) horizontally of the vertical center-line
alcove, courtyard or other recessed area. of the regulator.
10. DO NOT terminate above any door, window, or e. Within 6 ft (1.8 m) of any gas service regulator
gravity air intake. Condensate can freeze, causing vent outlet.
ice formations. f. Less than 1 ft (30. 5 cm) above grade level.
11. Locate or guard vent to prevent condensate from g. Within 3 ft (91.4 cm) of a window or door
damaging exterior finishes. Use a rust resistant which can be opened in any building, any non-
sheet metal backing plate against brick or masonry mechanical air supply inlet to any building or the
surfaces. combustion air inlet of any other appliance.
12. DO NOT extend exposed vent pipe outside of h. Underneath a veranda, porch or deck, unless
building. Condensate could freeze and block vent
pipe. i. the veranda, porch or deck is fully open on a
minimum of two sides beneath the floor, and
US Installations ii. the distance between the top of the vent
Refer to latest edition of the National Fuel Gas Code. termination and the underside of the
Vent termination requirements are as follows: veranda, porch or deck is greater than 1 ft.
(30.5 cm).
a. Vent must terminate at least 4 ft (1.2 m) below, 4
ft (1.2 m) horizontally, or 1ft (30.5 cm) above any
door, window or gravity air inlet to the building.

22
 Code (Canada). The minimum flue pipe diameter for
Venting Installation Tips conventional negative draft venting using double-wall
Support piping: B type vent is 4" for HD101 and HD151, 5" for HD201,
• horizontal runs- at least every 5 ft (1.5 m). HD251 and HD301, and 6" for HD401.

• vertical runs - use braces: NOTE: Use a field-supplied single-wall to double-wall

adapter to connect B-vent to the unit.
• under or near elbows
Follow items listed below to avoid personal injury or The connection from the appliance vent to the stack must
property damage. be as direct as possible and shall be the same diameter
• Cut nonmetallic intake pipe with fine-toothed as, or larger than the vent outlet. The horizontal breaching
hacksaw. of a vent must have an upward slope of not less than 1/4
inch per linear foot from the heater to the vent terminal.
• Do not use nonmetallic intake pipe or fittings that The horizontal portions of the vent shall also be supported
are cracked or damaged. for the design and weight of the material employed to
• Do not use nonmetallic intake fittings if they are cut maintain clearances and to prevent physical damage or
or altered. separation of joints.
• Do not drill holes, or use screws or rivets, in NOTE: When an existing category I applicance is
nonmetallic intake pipe or fittings. removed or replaced, the original venting system
To make metallic vent joints: may no longer be sized to properly. Improperly sized
venting system can cause formation of condensate,
• Do not install seams of vent pipe on bottom of runs. leakage and spillage, etc.
• 100% Seal all joints and seams with high
temperature silicone sealant. 8' (2.4 m) OR
VENT CAP
LESS
A  WARNING: Examine the venting system at least
once a year. Check all joints and vent pipe connections
for tightness, corrosion or deterioration. 2' (61 cm)
MIN
2' (61 cm) MIN
NOTE: The words “Flue Exhaust”, “Flue” and
“Exhaust Vent” are used interchangeably.

Venting Configurations
For heaters connected to gas vents or chimneys, vent
installations shall be in accordance with the section on,
VENT PIPE
Venting of Equipment, of the latest edition of NFGC,
or in Canada, B149 Installation Code for Gas Burning
Appliances and Equipment, or applicable provisions of
local building codes.
Natural Draft Vertical Venting System COMBUSTION
Installation AIR FILTER

Natural draft venting uses the natural buoyancy of

the heated flue products to create a thermal driving
head that expels the exhaust gases from the flue. The
negative draft must be within the range of –0.01 in. to
BOILER UNIT
–0.08 in. WC as measured 12 in. (30.5 cm) from the
appliance flue outlet to ensure proper operation. Vent
material must be listed by a nationally recognized test
agency. F10074

The maximum and minimum venting length for Category

I appliance shall be determined per the latest edition of Figure 20. Natural Draft Vertical Venting (Category I)
the NFGC (U.S.) or B149 Installation Code (Canada).
Use the "FAN" column of the standard venting tables. Natural Draft Vertical Vent Termination
The diameter of vent flue pipe should be sized according The vent terminal should be vertical and should terminate
to Part 11 of the latest edition of the NFGC (U.S.) outside the building at least 2 ft (61 cm) above the highest
and part 7 and appendix B of the B149 Installation point of the roof that is within 10 ft (3.0 m). The vent cap

23
should have a minimum clearance of 4 ft (1.2) horizontally and windows and all doors between the space in
from and in no case above or below (unless a 4 ft (1.2 which the appliances remaining connected to the
m) horizontal distance is maintained) electric meters, gas common venting system are located and other
meters, regulators and relief equipment. The distance spaces of the building. Turn on clothes dryers
of the vent terminal from adjacent public walkways, and any appliance not connected to the common
adjacent buildings, open windows and building openings vent system. Turn on any exhaust fans, such as
must be consistent with the NFGC, or in Canada, the range hoods and bathroom exhausts, so they
B149 Installation Code for Gas Burning Appliances and will operate at maximum speed. Do not operate
Equipment. Gas vents supported only by flashing and summer exhaust fan. Close fireplace dampers.
extended above the roof more than five feet should be d. Place in operation the appliances being
securely guyed or braced to withstand snow and wind inspected. Follow the manufacturers instructions
loads. for lighting each appliance. Adjust thermostat so
Natural Draft Vertical Venting with Common appliance will operate continuously.
Venting System, Category I Appliance Only e. Check the pressure at a pressure tap located 12
in. (30.5 cm) above the bottom joint of the first
Manifolds that connect more than one heater to a common
vertical vent pipe. Pressure should be anywhere
chimney must be sized to handle the combined load.
between -.01 to -.08 in. WC.
Consult available guides for proper sizing of the manifold
and the chimney. At no time should the area of the vent be f. After it has been determined that each appliance
less than the area of the largest heater exhaust outlet. remaining connected to the common venting
system properly vents when tested as outlined
A WARNING: Vent connectors serving appliances
above, return doors, windows, exhaust fans,
vented by natural draft shall not be connected into any
portion of mechanical draft systems operating under a
fireplace dampers and other gas burning
positive pressure. appliances to their previous conditions of use.
g. Any improper operation of the common venting
CAUTION: Vent connectors for natural draft venting
A  system should be corrected so that the installation
systems must be type “B” vent or better. conforms with the latest edition of the NFGC
(US) and the B149 Installation Code (Canada).
Common venting systems may be too large when an
When re-sizing any portion of the common
existing unit is removed. At the time of removal of an
venting system, the common venting system
existing appliance, the following steps must be followed
should be re-sized to approach the minimum
with each appliance remaining connected to the common
size as determined using the appropriate tables
venting system placed in operation, while the other
in Appendix G in the NFGC (US) and Appendix B
appliances remaining connected to the common venting
of the B149 Installation Code (Canada).
system are not in operation.
a. Seal any unused opening in the common venting Horizontal Thru-wall Venting System
system.
(Category III) Installation
b. Visually inspect the venting system for proper
These installations utilize the heater-mounted blower to vent
size and horizontal pitch and determine there is
the combustion products to the outdoors. Combustion air is
no blockage or restriction, leakage, corrosion or
taken from the space and the vent is installed horizontally
other unsafe condition.
through the wall to the outdoors. Adequate combustion
c. Insofar as is practical, close all building doors and ventilation air must be supplied in accordance with the

Certified Minimum Min./Max. Venting Length without

Model Appliance Barometric Damper (ft / m)** Air Inlet Max.
Venting Recommended Vent
No. Category Length (feet)
Material Size (inches) Min. Max.
HD101
4 6 (1.8)
HD151
HD201 I Type B or
6 (1.8 m) 25 (7.6) 100 (30.5)
HD251 Fan-assisted Equivalent 5
HD301 11 (3.4)
HD401 6 8 (2.4)

**Vent lengths are based on a lateral length of 2 feet (61 cm). Refer to the latest edition of the NFGC for further details. (ANSI Z223.1)
Maximum 4 elbows.
Table K. Natural Draft Vertical Venting

24
NFGC or, in Canada, the B149 Installation Code. maintain clearances and to prevent physical damage
The total length of the horizontal thru-wall exhaust vent or separation of joints. They shall also be adequately
system should not exceed 100 ft (30.5 m) in length. If supported to prevent sagging.
horizontal run exceeds 100 ft (30.5 m), an appropriately The vent must be installed to prevent the potential
sized extractor must be used. Each elbow used is equal to accumulation of condensate in the vent pipes. It is
10 ft (3.0 m) of straight pipe. This will allow installation in recommended that:
one of the four following combinations. a. The vent be installed with a slight downward
• 100' (30.5 m) of straight flue pipe. slope of not more than 1/4" per foot of horizontal
• 90' (27.4 m) of straight flue pipe and one elbow. run to the vent terminal.

• 80' (24.4 m) of straight flue pipe and two elbows. b. The vent be insulated through the length of the
horizontal run.
• 70' (21.3 m) of straight pipe and three elbows.
For appliances installed in extreme cold climate, it is
• 60' (18.3 m) of straight pipe and four elbows. recommended that:
The vent cap is not considered in the overall length of the a. The vent be installed with a slight upward slope
venting system. The vent must be installed to prevent the of not more than 1/4" per foot of horizontal run
flue gas leakage. Care must be taken during assembly to to the vent terminal. In this case, an approved
ensure that all joints are sealed properly and are airtight. condensate trap must be installed per applicable
The horizontal portions of the vent shall also be supported codes.
for the design and weight of the material employed to b. The vent be insulated through the length of the
horizontal run.

12" MIN
(30.5 cm)
INSULATED EXHAUST
VENTING

D-15 FLUE
EXHAUST
VENT CAP

CONDENSATE
DRAIN AND TRAP
12" MIN
(30.5 cm)

BOILER
UNIT

F10075

Figure 21. Horizontal Thru-Wall Venting (Category III)

Certified Max. Venting

Model Appliance Vent Size
Venting Length
No. Category (inches)
Material ft (m)
HD101
4
HD151
HD201 Stainless Steel
III 100 (30.5)
HD251 (Gas Tight) 5
HD301
HD401 6

Maximum 4 elbows.
Table L. Horizontal Thru-Wall Venting (Category III)

25
 Combustion air supplied from outdoors must be free of
Horizontal Thru-wall Direct Vent particulate and chemical contaminants. To avoid a blocked
Termination flue condition, keep the vent cap clear of snow, ice, leaves,
The flue exhaust direct vent cap MUST be mounted on debris, etc.
the exterior of the building. The direct vent cap cannot be A  WARNING: No substitutions of flue pipe or vent
installed in a well or below grade. The direct vent cap must cap material are allowed. Such substitutions would
be installed at least 1 ft (30.5 cm) above ground level and jeopardize the safety and health of inhabitants.
above normal snow levels.
Multiple direct vent caps MUST NOT be installed with The flue exhaust direct vent cap must be furnished by
one combustion air inlet directly above a direct vent the heater manufacturer in accordance with its listing.
cap. This vertical spacing would allow the flue products Use only the special gas vent pipes listed for use with
from the direct vent cap to be pulled into the combustion Category III gas burning heaters, such as the stainless steel
air intake installed above. This type of installation can vent by Heat Fab Inc (800-772-0739), Protech Systems,
cause non warrantable problems with components and Inc. (800-766-3473) or Z-Flex (800-654-5600). Pipe joints
poor operation of the unit due to the recirculation of flue must be positively sealed. Follow the vent manufacturers
products. Multiple direct vent caps should be installed in installation instructions carefully.
the same horizontal plane with a 3 ft (91.4 cm) clearance Raypak does not support common venting under Catagory
from the side of one vent cap to the side of the adjacent III (positive-pressure) conditions.
vent cap(s).
Certified Max. Venting Combustion Max. Air
Appliance Vent Size Air Inlet Size
Model No. Venting Length Air Intake Pipe Intake Length
Category (inches) (inches)
Material ft (m) Material (ft/m)
HD101
4 Galvanized
HD151
Stainless Steel
HD201 100 (30.5)
III Steel PVC 4 100 (30.5)
HD251 5 4 Elbows Max.
(Gas Tight) ABS
HD301
CPVC
HD401 6

Maximum 4 elbows, for either intake or vent.

Table M. Horizontal Thru-Wall Venting

CAT III 12" MIN

VENT (30.5 cm)
PIPE D-15
FLUE EXHAUST
VENT CAP

CONDENSATE
INTAKE DRAIN AND TRAP
VENT 36" MIN
(91.4 cm)
COMBUSTION
AIR FILTER

6"
(15.2 cm)
12" MIN
(30.5 cm)

BOILER
UNIT

F10076

Figure 22. Direct Vent Horizontal Thru-Wall Venting (Category III)

26
Vertical Direct Vent System Installation Outdoor Installation
These installations utilize the heater-mounted blower to Outdoor models are self-venting when installed with
draw combustion air from outdoors and uses the natural the factory-supplied vent assembly and air intake cover
buoyancy of the heated flue products to create a thermal and require no additional vent piping. This special vent
driving head that expels the exhaust gases from the flue. assembly is provided with the heater in accordance with
The negative draft must be within the range of -0.01 to -0.08 CSA requirements. It must be installed directly on the
in. WC as measured 12 in. (30.5 cm) from the appliance heater. See the Venting section starting from 20 for
outlet to ensure proper operation. The vent material must correct clearances.
be in accordance with the above instructions for vent Care must be taken when locating the outdoor unit because
materials. Vent material must be listed by a nationally the flue gases discharged from the vent assembly can
recognized test agency. condense as they leave the assembly. Improper location
The maximum and minimum venting length for Category I can result in damage to adjacent structures or building
appliance shall be determined per the latest edition of the finish. For maximum efficiency and safety, the following
NFGC (U.S.) and B149 Installation Code (Canada). precautions must be observed:
The connection from the appliance exhaust vent to the a. Outdoor models must be installed outdoors and
stack must be as direct as possible and should be the must use the outdoor vent assembly and air
same as or larger than the vent outlet. The vent must intake cover supplied by the manufacturer.
be installed to prevent accumulation of condensate and, b. Periodically check venting system. The heater’s
where necessary, have means provided for drainage of venting areas must never be obstructed in
condensate. The horizontal breaching of a vent must have any way and minimum clearances must be
an upward slope of not less than 1/4 inch per linear foot observed to prevent restriction of combustion
from the heater to the vent terminal. The horizontal portions and ventilation air. Keep area clear and free of
of the vent shall also be supported for the design and combustible and flammable materials.
weight of the material employed to maintain clearances
and to prevent physical damage or separation of joints. c. Do not locate adjacent to any window, door
walkway, or gravity air intake. The vent must be
Vertical Direct Vent Termination located a minimum of 4 ft (1.2 m) horizontally, or
4 ft (1.2 m) below, or 1 ft (30.5 cm) above such
The exhaust vent terminal should be vertical and should
areas.
terminate outside the building at least 2 ft (61 cm) above
the highest point of the roof within 10 ft (3 m). The vent d. Install above grade level and above normal
cap should have a minimum clearance of 4 ft (1.2 m) snow levels.
horizontally from and in no case above or below (unless e. Vent must be at least 3 ft (91.4 cm) above any
a 4 ft (1.2 m) horizontal distance is maintained) electric forced air inlet located within 10 ft (3 m).
meters, gas meters, regulators and relief equipment.
The distance of the vent terminal from adjacent public f. Adjacent brick or masonry surfaces must be
walkways, adjacent buildings, open windows and building protected with a rust-resistant sheet metal plate.
openings must be consistent with the NFGC, or in Canada, g. Multiple Outdoor Vent installations require a 4 ft
the B149 Installation Code. Gas vents supported only by (1.2 m) clearance between vent assemblies.
flashing and extended above the roof more than five feet
NOTE: Condensate can freeze on the vent assembly.
should be securely guyed or braced to withstand snow Frozen condensate on the vent assembly can result in a
and wind loads. blocked flue condition.
The vertical vent cap is designed for roof top mounting
only. The air inlet opening MUST be installed 1 ft (30.5 cm) The vent assembly must be furnished by the heater
above the roof line or above normal snow levels that might manufacturer in accordance with its listing.
obstruct combustion air flow. This dimension is critical to
the correct operation of the heater and venting system
and reduces the chance of blockage from snow. The vent
cap must have a minimum 3 ft (91.4 cm) clearance from
the air inlet opening.

27
 36" MIN
(91.4 cm)

36" MIN 12" MIN

(91.4 cm) (30.5 cm)

VENT
PIPE
INTAKE
VENT

COMBUSTION
AIR FILTER

BOILER
UNIT

F10077

Figure 23. Direct Vent—Vertical Venting (Category I)

Certified Min./Max. Vertical Combustion Air Inlet Max. Air

Appliance Vent Size Venting Height (feet)
Model No. Venting Air Intake Size Intake Length
Category (inches)
Material Min. Max. Pipe Material (inches) (feet)
HD101
4 6 Galvanized
HD151
Steel
HD201 Type B (HD201) 6
I 25* PVC 4 100
HD251 Equivalent 5 (HD251) 6
ABS
HD301 (HD301) 11
CPVC
HD401 6 8

*Over 25 feet, use single acting barometric damper. Consult the factory for additional information.
Maximum 4 elbows, for either intake or vent.
Table N. Vertical Venting

28
5. CONTROLS Outdoor Air Reset Temperature
A  WARNING: Installation, adjustment and service of Controller
heater controls including timing of various operating
Models HD101 through HD301 Type H are equipped with
functions must be performed by a qualified installer,
service agency or the gas supplier. Failure to do so may
an electronic outdoor air reset temperature controller as a
result in control damage, heater malfunction, property standard feature. This controller is also available as sales
damage, personal injury, or death. option B-42 for model HD401 and for all Type WH models.
The standard configuration provides for outdoor air reset
WARNING: Turn off the power to the heater before
A  of the system target water temperature based on a user-
installation, adjustment or service of the heater controls. defined reset ratio. The controller will reset between 120°F
Failure to do so may result in heater malfunction, (49°C) and 200°F (93°) system water temperature and
property damage, personal injury, or death.
allow for a maximum boiler outlet of 210°F (99°C). The
controller will provide two-stage firing of an H3 boiler.
A  CAUTION: This appliance has provisions to be
The controller is also equipped with a connection for an
connected to more than one (1) supply source. To
reduce the risk of electric shock, disconnect all such external thermostat input for use with an indirect load such
connections before servicing. as an indirect DHW tank for hot water production. When
used for direct DHW in conjunction with a storage tank,
A  CAUTION: Risk of electric shock. More than one (1) the controller can be configured to provide fixed setpoint
disconnect switch may be required to de-energize the operation.
equipment before servicing.
The primary functions of the controller are set using the
Operating Temperature dial and the DIP switches. See
Table P. The controller has 4 LEDs to indicate its condition:
Ignition Control Module
Power - On Solid - Turns on when 24 Vac Power is
The interrupted proved ignition device conserves energy.
present.
When additional heat is needed, the combustion air
blower starts to purge all air from the combustion chamber Heat Call - On Solid - Turns on when Heat Call (short
for about 15 seconds. On proof of air flow, the air proving or 0-32 Vac) is present.
switch closes and the igniter is energized, eliminating the Flashing - Boiler outlet sensor error. While
fuel costs of maintaining a constant pilot. present, operation ceases.
To ensure safe operation, the gas valve cannot open until IND Call - (Indirect DHW) On Solid - Turns on when
the igniter is verified as capable of igniting the gas. The IND Call (short or 0-32 Vac) is present.
ignition module is an electronic device which closes the
main gas valve within 8/10 of a second whenever the Flashing - System supply sensor error. While
flame is interrupted. The main burner is automatically lit present, operation continues using boiler outlet
when the device is powered and pre-purged. The unit sensor.
performs its own safety check. WWSD - On Solid - Turns on when in Outdoor Reset
AND WWSD Active AND control in WWSD.
Flashing - Outdoor sensor error. While
present, operation continues with Fixed boiler
target of 140 based on 32°F.

Figure 24. Ignition Module

LED FAULT
ON Control fault
1 flash Air flow fault
2 flashes Flame / no call for heat
3 flashes ignition lockout

Table O. Flash Codes

29
 Item Feature Setting / Description Default
Operating Reset Ratio
Dial Reset Ratio 0.4 to 3.6 / Setpoint Target 120°F to 200°F
Temperature 0.4 to 3.6
Single Stage
DIP #1 Firing Mode Single Stage (On) / Two Stage (Off)
(On)
Outdoor Reset
DIP #2 Configuration Outdoor Reset (On) / Setpoint (Off)
(On)
Warm Weather Active 70°F (21°C)
DIP #3 Active 70°F (21°C) (On) / Inactive (Off)
Shut Down (On)
Boiler Maximum (dependent on DIP #5) - Default: On
Boiler Max Outlet 190°F (88°C)
DIP #4 • If DIP #5 set to Hydronic (On): 210°F (99°C) (Off) / 190°F (88°C) (On)
Setting (On)
• If DIP #5 set to Direct DHW (Off): 180°F (82°C) (Off) / 160°F (71°C) (On)
Space Heating or Direct DHW (Off) / Hydronic (On) - Default: Hydronic (On)
Hydronic
DIP #5 Direct Domestic Note: If DIP #5 is set to Direct DHW (Off), the operation is based on
(On)
Hot Water Setpoint regardless of DIP #2 setting.

Table P. Outdoor Air Reset Temperature Controller Settings

Hydronic, Outdoor Air Reset with Indirect

Hydronic with Outdoor Air Reset DHW
For hydronic operation with outdoor air reset, the System For hydronic operation with outdoor air reset and Indirect
Supply Sensor (S2) is used as the operating sensor. Boiler DHW, the System Supply Sensor (S2) is used as the
Outlet Sensor (S1) is used for boiler outlet maximum operating sensor. Boiler Outlet Sensor (S1) is used for
limiting. Boiler Pump (P1) is controlled by the boiler and is boiler outlet maximum limiting. Contact closure from an
cycled off using a 5 minute fixed purge delay after burner aquastat (A1) located on an indirect DHW tank will cause
operation has ceased. the controller to operate to a boost temperature to satisfy
the indirect call for heat. Once the aquastat opens, the
controller will return to normal operation. The indirect pump
is operated by an external relay (by others). The Boiler
Pump (P1) is controlled by the boiler and is cycled off using
a fixed 5-minute purge delay after burner operation has
ceased.

Figure 25. Hydronic with Outdoor Air Reset

S1 = Boiler Outlet Sensor

S2 = System Supply Sensor
S3 = Outdoor Air Sensor
Figure 26. Hydronic with Outdoor Air Reset and Indirect
P1 = Boiler Pump
DHW
The DIP switch settings are as follows:
DIP 1 ON (ON/OFF) – OFF (2-STAGE) The DIP switch settings are as follows:

DIP 2 ON (OUTDOOR RESET) DIP 1 ON (ON/OFF) – OFF (2-STAGE)

DIP 3 ON (WWSD 70°F) DIP 2 ON (OUTDOOR RESET)

DIP 4 ON (190°F BOIL MAX) DIP 3 ON (WWSD 70°F)

DIP 5 ON (HYDRONIC) DIP 4 ON (190°F BOIL MAX)

DIP 5 ON (HYDRONIC)

30
Direct Domestic Hot Water High Limit (Manual Reset)
In this configuration the controller will operate to maintain The heater is equipped with a manual reset high limit
a set temperature in the storage tank. The differential is temperature device. If the optional adjustable limit is used,
fixed at 5°F (3°C) below target. The System Supply Sensor push the reset button and adjust the setting to 30°F (17°C)
(S2) is used as the operating sensor. Boiler Outlet Sensor or 40°F (22°C) above desired operating temperature.
(S1) is used for boiler outlet maximum limiting. Boiler
Pump (P1) is controlled by the boiler and is cycled off
using a 5 minute fixed purge delay after burner operation
has ceased.

Figure 29. Manual Reset High Limit

High Limit – Auto Reset (Optional)

This heater may be equipped with an optional adjust-able
Figure 27. Direct Domestic Hot Water auto reset high limit temperature device.
The optional adjustable auto reset high limit is located
The DIP switch settings are as follows: behind the front panel (see Figure 3). Adjust the setting
to approx. 20°F (11°C) above desired outlet temperature.
DIP 1 ON (ON/OFF) – OFF (2-STAGE)
DIP 2 OFF (SETPOINT)
DIP 3 OFF (WWSD INACTIVE)
DIP 4 ON (160°F [71°C] BOIL MAX)
DIP 5 OFF (DIRECT DHW)

Digital Temperature Control

The WH-101 thru WH-401 heaters can be equipped with
a Raypak digital temperature control. For operation with
this control, refer to the Temp-Tracker Installation and
Operating Instructions, Raypak P/N 241177.

Figure 30. High Limit — Auto Reset (Optional)

Figure 28. Digital Temperature Control

31
Flow Switch Low Water Cut Off (Optional)
Dual-purpose control shuts off heater in case of pump The low water cut off automatically shuts down the burner
failure or low water flow. Mounted and wired in series with whenever water level drops below the level of the sensing
the main gas valve. probe. A 5-second time delay prevents premature lockout
due to temporary conditions such as power fluctuations or
NOTE: Flow switch will not operate if flow is less than
12 gpm (45 lpm).
air pockets.

Figure 33. Low Water Cut Off

Figure 31. Flow Switch

High and Low Gas Pressure

Switches (Optional)
The low gas pressure switch (optional) connection mounts
upstream of the gas valve to ensure that sufficient gas
pressure is present for proper regulator performance. The
low gas pressure switch automatically shuts down the
heater if gas supply drops below the recommended setting
of 4.0 in. WC for natural gas, and 9.0 in. WC for propane
gas.
The high gas pressure switch (optional) connection
mounts down-stream of the gas valve. If the gas pressure
regulator fails, the high gas pressure switch automatically
shuts down the burner. The high gas pressure switch
automatically shuts down the heater if gas manifold
pressure rises above the recommended setting of 4.0 in.
WC for natural gas, and 10.5 in. WC for propane gas.

Figure 32. Gas Pressure Switch

32
 APPROVED
6. WIRING DIAGRAMS
Models HD101-HD151 Type WH1 ON/OFF

UNCONTROLLED DOCUMENT IF PRINTED

For Reference Only

33
Models HD101-HD151 Type H3 (2-Stage)

34
 APPROVED
Models HD201-HD401 Type WH1 (ON/OFF)

UNCONTROLLED DOCUMENT IF PRINTED

153155

For Reference Only

35
36
RELEASED
APPROVED
Models HD201-HD301 Type H3 (2-Stage)

UNCONTROLLED DOCUMENT IF PRINTED

For Reference Only

 APPROVED
Model HD401 Type H3 (2-Stage)

UNCONTROLLED DOCUMENT IF PRINTED

153156

For Reference Only

37
7. PRE-START-UP Preparation for Start-Up
WARNING: Do not turn on gas at this time.
A 
Filling System-Heating Heaters
Fill system with water. Purge all air from the system using
purge valve sequence. After system is purged of air, Check Power Supply
lower system pressure. Open valves for normal system
operation, fill system through feed pressure. Manually
open air vent on the compression tank until water appears,
then close vent.

Domestic Hot Water Heaters

Purge all air from system before lighting heater. This can
be normally be accomplished by opening a downstream
valve.
Figure 34. Check Power Source

Inspect Venting System: With volt meter at incoming power check voltage between:

1. Check all vent pipe connections and flue pipe Hot - Common (~120 VAC)
material. Hot - Ground (~120 VAC)
2. Ensure vent terminations are installed per code and Common - Ground (< 1 VAC)
are clear of all debris or blockage.
A  WARNING: If Common - Ground is > 1 VAC, STOP:
Contact electrician to correct ground failure. Failure
Pre-Start-Up Check to do this may burn out 120V-24V transformer, or may
1. Verify heater is filled with water. cause other safety control damage or failure.

2. Check system piping for leaks. If found, repair Attach Manometers to Measure Pressures
immediately.
• Attach 16" scale manometer to the main gas shut-off
3. Vent air from system. Air in system can interfere with valve supply pressure tapping.
water circulation.
• Attach one 12" scale manometer to the manifold gas
4. Purge air from gas line up to heater. pressure tapping. (See Figure 8.)
• Attach one 12" scale manometer to the tee near the
8. INITIAL START-UP blower housing.

Tools Needed Check the Gas Supply Pressure

• One 8–0–8, 16" scale manometer 1. Slowly turn on main gas shut-off valve.
• Two 6–0–6, 12" scale manometers 2. Read the gas supply pressure from the manometer;
• 7/16" open end wrench minimum supply pressure is 4 in. WC, recommended
supply is 7 in. WC for natural gas (minimum 11.0 in.
• 1/2" open end wrench WC for LP gas).
• Screwdriver (Standard & Phillips) 3. If pressure is > 14 in. WC, turn off the valve.
• 3/8" open end wrench 4. Check if the service regulator is installed and/or
• Multi-meter adjust the service regulator.
• 3/16" Allen wrench
• 3/32" Allen wrench (Honeywell or White-Rodgers Start-Up
gas valve)
Blower Adjustment
• 5/32" Allen wrench (Invensys gas valve)
1. A nylon tee fitting is connected with hoses in-line with
• #10 Torx driver w/center hole (Invensys gas valve) the air pressure switches. Disconnect the plugged
NOTE: Digital manometers are not recommended. side and connect a manometer.
2. Close the gas valve.
3. Turn power on.

38
4. During startup or Lo-Fire, the air pressure should 5. Main burner ignition – check manifold gas pressure
read 0.45 ±0.05 in. WC. During Hi-Fire, the reading at gas valve manifold pressure tap. (See Table Q).
should be between 0.9 in. WC and 1.2 in. WC. If these 6. If the pressure reading differs by more than the
are not the ob­­served manometer readings, adjust the tolerance given, adjust the gas valve accordingly. See
air shutter on the blower to attain the correct values. gas valve adjustment section below for instructions.
(See Figure 4, air shutter adjustment).
5. Turn power off. Gas Valve Adjustment
6. Reinstall rubber plug on tee.
Honeywell Gas Valve
1. While the heater is running, remove plastic cap
Main Burner Adjustment located behind ON/OFF knob.
1. Turn off unit. 2. Locate the HI or LO screw to adjust.
2. Open manual firing valve. 3. Using a small flat screwdriver, turn clockwise to
3. Turn on the unit, wait 15 seconds, and the igniter increase and counterclockwise to decrease manifold
should glow. There’s a sight glass to check igniter at pressure. See nominal gas valve manifold settings in
both ends of the heater. Gas valve should be open Table Q above.
after 45 seconds. 4. Replace plastic cap when pressure is set.
4. If burner does not light on first trial. It will retry, up to
3 times.

39
White Rodgers Gas Valve Gas Type Conversion on Valve
1. While the heater is running, locate the HI or LO cap A WARNING: Burner orifices must be changed when
located adjacent to ON/OFF switch. changing gas type.
2. Remove the appropriate cap.
NOTE: Model HD401 requires replacement of valve.
3. Using a flat screwdriver, turn clockwise to increase
and counterclockwise to decrease manifold pressure. 1. Turn off gas supply at the appliance service level.
See nominal gas valve manifold settings above.
2. Remove the pressure regulator cover assembly.
4. Replace cap(s) when pressure is set.
3. Remove the existing stem/spring assembly.
4. Insert the replacement stem/spring assembly.
Invensys (Model HD401 Natural Only)
5. Replace the pressure regulator cover assembly and
1. Turn heater off. tighten screws.
2. Locate and remove the Torx tamper resistant screw. 6. Mount conversion labels on the gas valve.
(Shown in Figure 35)
Gas Type
Firing
Gas Valve LP/
Stage Natural
Propane
Invensys 3.4" WC
Hi-Fire
+/- 0.2" WC Honeywell or
3.1" WC 9.6" WC
White-Rodgers
Invensys 1.1" WC
Lo-Fire
+/- 0.1" WC Honeywell or
1.2" WC 3.6" WC
White-Rodgers

Table Q. Gas Valve Pressures

Figure 35. Gas Valve Adjustment (Invensys Valve)

3. Carefully remove 2-stage solenoid.

4. Skip to Step 9 for LO-fire adjustment only.
5. Locate and remove Lo-fire adjustment cap.
6. Carefully remove the spring & weight.
7. Using an allen wrench, turn clockwise to increase and
counterclockwise to decrease the HI-fire manifold
pressure. Heater will not run while adjusting HI-fire Figure 36. Gas Type Conversion on Honeywell Valve
pressure.
8. Carefully place the spring & weight back in before
replacing LO-fire adjustment cap.
9. For LO-fire adjustment, tighten the cap to increase
the pressure, loosen to decrease.
10. When correct settings are set, replace the solenoid
and tamper screw in place.

40
 Gas Type Check off steps as completed:
Firing Expected
LP/ 1. Heater and heat distribution units or storage tank
Stage Settings Natural
Propane filled with water?
CO2 8.2 +/- 0.2% 9.7 +/- 0.3% 2. Automatic air vent, if used, open two full turns during
venting procedure?
Lo-Fire CO < 50ppm < 50 ppm
3. Air purged from system?
0.45" +/- 0.05"
Air 0.45" +/- 0.05" WC
WC 4. Air purged from gas piping? Piping checked for
CO2 8.7 +/- 0.2% 10.1 +/- 0.4% leaks?
Hi-Fire CO < 150ppm < 150ppm 5. Followed start-up procedure for proper start-up?

Air 1.05" +/- 0.1" WC 1.05" +/- 0.1" WC

6. Is burner flame visible?
7. Test safety controls: If heater is equipped with a low
Table R. Expected Settings water cut-off or additional safety controls, test for
operation as outlined by manufacturer. Burner should
Safety Inspection be operating and should go off when controls are
• Replace main gas manifold adjustment screw cap. tested. When safety devices are restored, burners
should reignite after pre-purge time delay.
• Check all thermostats and high limit settings.
8. Test limit control: While burner is operating, move
• During the following safety checks leave manometers indicator on high limit control below actual heater
hooked up, check and record. water temperature. Burner should go off while blower
• If other gas fired equipment are in the room and on and circulator continue to operate. Raise setting on
same gas main check all pressures on the Hi Delta limit control above heater water temperature and
SS with all other equipment running. burner should reignite after pre-purge time delay.
• Check thermostats for ON/OFF operation. NOTE: This test doesn’t apply to fixed setting high
limits.
• Check High limits for ON/OFF operation.
• While in operation, check flow switch operation. 9. Test ignition system safety device:
• Check the low gas pressure switches (For • Turn on manual gas valve. Turn power on.
proper adjustment, if available, use the attached • Set thermostat to call for heat.
manometers to set pressure. The scales on the
switch are approximate only); Low gas pressure • When the unit is in operation. Disconnect combustion
switch (optional) must be set at 3.5 in. WC for natural air blower pressure switch, burner should go off
gas and 10.5 in. WC for LP gas. immediately.
• High gas pressure switch (optional) at 1 in. WC above • Wait 5 minutes.
manifold pressure. • Reconnect combustion air pressure switch, burner
• Insert ignition control lockout tests as safety check. should reignite after pre-purge time delay.
10. To restart system, follow lighting instructions in the
Follow-Up Operation section.
• Safety checks must be recorded as performed. 11. Is the high limit control set to design temperature
requirements of system? For multiple zones: is flow
• Turn unit on.
adjusted as required in each zone?
After main burner ignition:
12. Heater cycled with thermostat? Raise to highest
• Check Manometer(s) for proper reading(s). setting and verify heater goes through normal start-
• Cycle unit several times and recheck readings. up cycle. Reduce to lowest setting and verify heater
goes off.
• Re-analyze with unit running record or print results.
13. Observed several operating cycles for proper
• Remove all Manometers and replace hose, replace operation?
all gas pressure caps.
14. Set room thermostat or tankstat to desired
• Check for gas leaks one more time. temperature?
9. POST START-UP CHECK 15. Reviewed all instructions shipped with this heater with
owner or maintenance person, returned to envelope
and given to owner?

41
Figure 37. Locate the Air Filter Panel

Figure 39. Inspect the Air Filter

Heat Exchanger Removal

Refer to Figure 40 for the following procedure.
1. Before beginning, make sure the heater is cool to the
touch. Shut water, gas and electricity off, close valves
and relieve pressure, then remove the relief valve.
Remove side inspection panels.
2. Remove screw behind inspection panels holding the
jacket top down.
3. Remove the front panel. Remove two additional
screws holding the jacket top to the top support.
4. Disconnect vent pipe from the flue exhaust and set
aside.
Figure 38. Remove the Screws and Panel 5. Remove jacket top, then disconnect vent switch hose.
6. Remove two rows of screws holding the flue collector
Air Filter Inspection/Removal to the combustion chamber. Remove two additional
screws located on the front combustion panel. Cut
1. Turn power off. any silicone holding the flue collector and heat
2. Locate the Air Filter panel below the air intake duct. exchanger in place.
3. Remove the (4) screws holding the panel in place. 7. Carefully lift and remove the flue collector.
4. Pull the air filter out for inspection. Replace if 8. Lift heat exchanger straight up being careful not to
necessary. damage the refractory.
5. Replace the panel and screws before operating. 9. Reverse the above procedure to re-install. Make sure
sufficient high temperature silicone sealant (RTV) is
placed along the vertical sides of the tube sheet and
flue collector.

42
 JACKET TOP 9. Follow oil-lubricating instructions on circulator (if
REMOVAL
required). Over-oiling will damage circulator. Water-
lubricated circulators do not need oiling.
10. To avoid potential of severe burn, DO NOT REST
HANDS ON OR GRASP PIPES. Use a light touch -
FLUE COLLECTOR
REMOVAL
return piping will heat up quickly.
11. Check blower and blower motor. Clean and oil as
necessary.
ACCESS
PANEL
12. Check for piping leaks around circulators, relief
REMOVAL
valves and other fittings. Repair, if found. DO NOT
use petroleum-based stop leak.
13. Check air filter and replace if necessary.

Daily:
1. Check that heater area is free from combustible
ACCESS
PANEL materials, gasoline, and other flammable vapors and
REMOVAL
liquids.
2. Check for and remove any obstruction to the flow of
combustion or ventilation air to heater.

Monthly:
Figure 40. Heat Exchanger Removal 1. Check for piping leaks around circulators, mixing
valves, relief valves, and other fittings. If found, repair
at once. DO NOT use petroleum-based stop leak
10. MAINTENANCE compounds.
Suggested Minimum Maintenance 2. Visually inspect burner flame.
Schedule: 3. Visually inspect venting system for proper function,
deterioration or leakage.
Regular service by a qualified service agency and
maintenance must be performed to ensure maximum 4. Check air vents for leakage.
heater operating efficiency. Maintenance as outlined below
may be performed by the owner. Quarterly:
1. Check relief valve. Refer to manufacturer’s
Yearly (Beginning of each heating season): instructions on valve.
1. Annual service call by qualified service agency. 2. Test low water cut-off, if used. Refer to manufacturer’s
2. Visually check top of vent for soot. Call service person instructions.
to clean. Some sediment at bottom of vent is normal. 3. Check the air filter; replace if necessary.
3. Visually inspect venting system for proper function, 4. Clean the screens in the vent terminal as applicable.
deterioration or leakage.
4. Check that heater area is free from combustible
materials, gasoline, and other flammable vapors and
liquids.
5. Check for and remove any obstruction to the flow of
combustion or ventilation air to heater.
6. Follow pre-start-up check in the Initial Start-up
section.
7. Visually inspect burner flame. Should see light blue
flame. Visually inspect hot surface igniter for damage,
cracking or debris build-up.
8. Check operation of safety devices. Refer to
manufacturer’s instructions.

43
11. TROUBLESHOOTING
HD101-HD401 Troubleshooting
Does the main power switch provide NO Check the switch, transformer
Step 1 power to the green power LED? and/or line voltage

YES NO
Is Disable connection intact? Reattach.

YES
NO Is temperature controller NO
Step 2 Is there a Call For Heat? installed?
Install.

YES
Check and correct power
NO Is there 120VAC at the pump or NO connections at main terminal
Step 3 Does the Pump come on?
pump relay contacts? block, circuit breaker panel or
pump relay.
YES

Check and correct power

Step 4 Does the combustion air NO Is there120 VAC at the blower, NO connections at main terminal
blower come on? between the red & white leads?
block, ignition module, circuit
breaker panel or blower relay.
NO
Check safeties, I.E. Flow switch, high
YES limit, vent switch, thermostat, etc.

Step 5 Is 24VAC at the NO side of NO Is blower pressure setting Correct the blower
NO
correct? Should be about 0.87” shutter setting.
the air pressure switch?
W.C. (low speed) NO

YES Is the air filter or

YES air intake blocked?
Replace low air pressure switch. YES

Is 24VAC at PS on ignition module? Remove blockage

Step 6 Is connecting plug secure? NO Correct wiring.
and/or replace filter

YES
Is Amp draw during heat-
NO NO
Step 7 Does igniter prove? up for HSI greater than Replace HSI
3.1 Amps?

YES NO
YES YES
Is air switch bouncing?

Is the flame sensor signal to the ignition NO NO

Step 8 Is inlet gas supply pressure Correct inlet gas supply pressure
module greater than 1 Micro Amp (µA) DC? correct?

YES NO Adjust manifold gas

YES
pressure.
Is manifold gas Yes
pressure correct? Replace gas valve
Does the unit run longer
Step 9 than 10 seconds?
YES Replace air pressure switch
Does the unit run at least YES Does the air pressure
NO
YES 5 seconds? reach 0.9” W.C.?

NO NO NO
Is the air filter or air Replace blower
Is the polarity of incoming
Step 10 The unit is okay power supply correct?
intake blocked?

NO YES YES Remove blockage

Correct supply wiring and/or replace filter
Is sensor probe grounded?

Call our Technical Service Department NO YES

1-800-947-2975 Outside California Replace Sensor
1-800-627-2975 Inside California

44
12. ILLUSTRATED PARTS LIST

45
 HEAT EXCHANGER DETAIL

CONTROL ASSEMBLY DETAIL

46
GAS TRAIN DETAIL

LIGHT PANEL DETAIL

47
 CALL
OUT DESCRIPTION HD101 HD151 HD201 HD251 HD301 HD401
B BURNER ASSEMBLY**
1-B Burner Assy w/Burners (Includes Front Comb Panel) 012810F 012811F 012812F 012813F 012814F 012815F
2-B Burner Worgas 012817F 012817F 012817F 012817F 012817F 012817F
3-B Seal Gasket 007443F 007443F 007443F 007443F 007443F 007443F
4-B Upper Manifold 012818F 012818F 012818F 012818F 012818F 012818F
5-B Lower Manifold 012819F 012820F 012821F 012822F 012823F 012824F
6-B Gas Manifold Grommet 3/4" NPT 010778F 010778F 010778F 010778F 010778F 010778F
7-B Burner Orifice Nat.#26 351632 / 2 351632 / 3 351632 / 4 351632 / 5 351632 / 6 351632 / 8
Burner Orifice Pro. (.084") 351671 / 2 351671 / 3 351671 / 4 351671 / 5 351671 / 6 351671 / 8
C CONTROLS
1-C Auto Reset Adjustable High Limit 240F Max 007141F 007141F 007141F 007141F 007141F 007141F
Auto Reset Adjustable High Limit 180F Max 006445F 006445F 006445F 006445F 006445F 006445F
Auto Reset Adjustable High Limit 200F Max 012546F 012546F 012546F 012546F 012546F 012546F
2-C Manual Reset Adjustable High Limit 240F 007144F 007144F 007144F 007144F 007144F 007144F
Manual Reset Adjustable High Limit 200F 008081F 008081F 008081F 008081F 008081F 008081F
3-C Manual Reset Fixed High Limit 240F 008520F 008520F 008520F 008520F 008520F 008520F
Manual Reset Fixed High Limit 200F 008093F 008093F 008093F 008093F 008093F 008093F
4-C Remote Aquastat (Tankstat) (B-2) 007148F 007148F 007148F 007148F 007148F 007148F
Remote Aquastat (Tankstat) 2-Stage (B-3) 007392F 007392F 007392F 007392F 007392F 007392F
5-C Controller 2-Stage (B-6) 007392F 007392F 007392F 007392F 007392F 007392F
Controller On/Off (B-20) 006445F 006445F 006445F 006445F 006445F 006445F
6-C Controller 4-Stage B-21 / B-23 Digital Optional 012691F 012691F 012691F 012691F 012691F 012691F
Controller 2-Stage B-26 / B-27 Digital Optional 012692F 012692F 012692F 012692F 012692F 012692F
Controller On/Off (B-28) Digital 009729F 009729F 009729F 009729F 009729F 009729F
7-C Controller RayTemp (B-25) 010252F 010252F 010252F 010252F 010252F 010252F
15-C Controller 2-Stage w/Outdoor Reset B-42 Digital 014279F 014279F 014279F 014279F 014279F 014279F
8-C Sensor Outdoor Air B-23 / B-27 / B-42 010786F 010786F 010786F 010786F 010786F 010786F
9-C Sensor Water B-21 thru B-27 and B-42 010787F 010787F 010787F 010787F 010787F 010787F
10-C Flow Switch 007142F 007142F 007142F 007142F 007142F 007142F
11-C Flow Switch Paddle (Taco) 010026F 010026F 010026F 010026F 010026F 010026F
12-C Switch Air Pressure N.C. (Vent) 007158F 007158F 012838F 012838F 012838F 012838F
13-C Switch Air Pressure Low N.O. (Blower) 012838F 012838F 012838F 012838F 012838F 012838F
14-C Switch Air Pressure High N.O. (Blower) 012837F 012837F 012837F 012837F 012837F 012837F
F FAN
1-F Blower Combustion Air (H3 & WH3)
Units manufactured prior to 1/1/16 012839F 012839F 015767F 015767F 015767F 015767F
Units manufactured from 1/1/16 012839F 012839F 012840F 012840F 012840F 012840F
Blower Combustion Air (WH1) 012839F 012839F 012840F 012840F 012840F 012840F
2-F Blower Gasket 012841F 012841F 012841F 012841F 012841F 012841F
3-F Air Shutter 012842F 012842F 012825F 012825F 012825F 012825F
4-F Hose Duct 4" 007417F 007417F 007417F 007417F 007417F 007417F
5-F Filter Media Pleated 6 x 6 N/A N/A N/A N/A N/A N/A
Filter Media Polyester Mesh 6 x 6 012843F 012843F 012843F 012843F 012843F 012843F
6-F Intake Air Vent Cap w/Screen 012844F 012844F 012844F 012844F 012844F 012844F
G GAS TRAIN
1-G Combination Gas Valve 2 Stage Nat Honeywell 012845F 012845F 012845F 012845F 012845F N/A
Combination Gas Valve 2 Stage Pro Honeywell 012846F 012846F 012846F 012846F 012846F 012846F
Combination Gas Valve 2 Stage Nat White Rodgers 012847F 012847F 012847F 012847F 012847F N/A
Combination Gas Valve 2 Stage Pro White Rodgers 012848F 012848F 012848F 012848F 012848F 012848F
Combination Gas Valve 2 Stage Nat Robershaw / Invensys N/A N/A N/A N/A N/A 012849F
Combination Gas Valve On/Off Nat Honeywell 007424F 007424F 007424F 007424F 007424F N/A
Combination Gas Valve On/Off Pro Honeywell 007425F 007425F 007425F 007425F 007425F 007425F
Combination Gas Valve On/Off Nat Robershaw / Invensys N/A N/A N/A N/A N/A 007666F
2-G Switch Low Gas Pressure (Optional) 007187F 007187F 007187F 007187F 007187F 007187F
3-G Switch High Gas Pressure (Optional) 007188F 007188F 007188F 007188F 007188F 007188F
H HEAT EXCHANGER
1-H Heat Exch Cast Iron 012850F 012851F 012852F 012853F 012854F 012855F
Heat Exch Brass Copper
H Boilers 012856F 012857F 012858F 012859F 012860F 012861F
WH1/WH3 Water Heaters (Units manufactured to 3/31/17) 012856F 012857F 012858F 012859F 012860F 012861F
WH1 Water Heaters (Units manufactured from 4/1/17) 016520F 016521F 016522F 016523F 016524F 016525F
WH3 Water Heaters (Units manufactured from 11/1/17) 012856F 012857F 012858F 012859F 012860F 012861F
Heat Exch Cast Iron Cupronickel 012862F 012863F 012864F 012865F 012866F 012867F
Heat Exch Brass Cupronickel
H Boilers 012868F 012869F 012870F 012871F 012872F 012873F
WH Water Heaters (Units manufactured to 3/31/17) 012868F 012869F 012870F 012871F 012872F 012873F
WH1 Water Heaters (Units manufactured from 4/1/17) 016526F 016527F 016528F 016529F 016530F 016531F
2-H Inlet/Outlet Header Cast Iron 012874F 012874F 012874F 012874F 012874F 012874F
Inlet/Outlet Header Brass 012875F 012875F 012875F 012875F 012875F 012875F
3-H Return Header Cast Iron 002042F 002042F 002042F 002042F 002042F 002042F
Return Header Brass 002043F 002043F 002043F 002043F 002043F 002043F
4-H Tube Bundle Copper
H Boilers 012876F 012877F 012878F 012879F 012880F 012881F
WH1/WH3 Water Heaters (Units manufactured to 3/31/17) 012876F 012877F 012878F 012879F 012880F 012881F
WH1 Water Heaters (Units manufactured from 4/1/17) 016532F 016533F 016534F 016535F 016536F 016537F
WH3 Water Heaters (Units manufactured from 11/1/17) 012876F 012877F 012878F 012879F 012880F 012881F
Tube Bundle Cupronickel
H Boilers 012882F 012883F 012884F 012885F 012886F 012887F
WH Water Heaters (Units manufactured to 3/31/17) 012882F 012883F 012884F 012885F 012886F 012887F
WH1 Water Heaters (Units manufactured from 4/1/17) 016538F 016539F 016540F 016541F 016542F 016543F
5-H Heat Exchange Tube Copper Heat 012888F 012889F 012890F 012891F 012892F 012893F
Exchange Tube Cupronickel 012894F 012895F 012896F 012897F 012898F 012899F
6-H Baffle Kit
H Boilers 012900F 012901F 012902F 012903F 012904F 012905F
WH1/WH3 Water Heaters (Units manufactured to 3/31/17) 012900F 012901F 012902F 012903F 012904F 012905F
WH1 Water Heaters (Units manufactured from 4/1/17) 016544F 016545F 016546F 016547F 016548F 016549F
WH3 Water Heaters (Units manufactured from 11/1/17) 012900F 012901F 012902F 012903F 012904F 012905F
7-H Stud Bolt Kit 007870F 007870F 007870F 007870F 007870F 007870F
8-H Header Gasket 800203B 800203B 800203B 800203B 800203B 800203B
9-H Sensor Well 007211F 007211F 007211F 007211F 007211F 007211F
10-H Well Retaining Clip 300203 300203 300203 300203 300203 300203
*FOR ALTITUDES ABOVE 4,500 FEET, CONSULT THE FACTORY

48
 CALL
OUT DESCRIPTION HD101 HD151 HD201 HD251 HD301 HD401
J CONTROL BOX
1-J Control Assy N/A N/A N/A N/A N/A N/A
2-J Ignition Control 008472F 008472F 008472F 008472F 008472F 008472F
3-J Transformer 100VA 007494F 007494F 007494F 007494F 007494F 007494F
4-J Pump Delay 5 or 10 Minutes 012551F 012551F 012551F 012551F 012551F 012551F
5-J Blower Relay 011720F 011720F 011720F 011720F 011720F 011720F
6-J Alarm Relay 011720F 011720F 011720F 011720F 011720F 011720F
7-J Terminal Block (3 Space) 008523F 008523F 008523F 008523F 008523F 008523F
8-J Terminal Block (2 Space) 011763F 011763F 011763F 011763F 011763F 011763F
10-J Time Delay Relay 008921F 008921F 008921F 008921F 008921F 008921F
9-J On/Off Switch 006872F 006872F 006872F 006872F 006872F 006872F
M MISCELLANEOUS
2-M PRV 30 PSI 007470F 007470F 007470F 007470F 007470F 007470F
PRV 45 PSI 007220F 007220F 007220F 007220F 007220F 007220F
PRV 60 PSI 007222F 007222F 007222F 007222F 007222F 007222F
PRV 75 PSI 007223F 007223F 007223F 007223F 007223F 007223F
PRV 125 PSI 008091F 008091F 007224F 007224F 007224F 007224F
PRV 150 PSI 007225F 007225F 007225F 007225F 007225F 007225F
3-M Deliming Kit 052871F 052871F 052871F 052871F 052871F 052871F
4-M T & P Gauge 0-90 PSI 007205F 007205F 007205F 007205F 007205F 007205F
T & P Gauge 0-200 PSI 007399F 007399F 007399F 007399F 007399F 007399F
T & P Gauge 0-230 PSI 014221F 014221F 014221F 014221F 014221F 014221F
5-M Sight Window Plug 008474F 008474F 008474F 008474F 008474F 008474F
6-M Window Combustion Chamber 006947F 006947F 006947F 006947F 006947F 006947F
7-M Ignitor 007400F 007400F 007400F 007400F 007400F 007400F
8-M Flame Sensor 006535F 006535F 006535F 006535F 006535F 006535F
9-M Status Light Decal 012906F 012906F 012906F 012906F 012906F 012906F
10-M RTV Sealant 2.8 oz 008924F 008924F 008924F 008924F 008924F 008924F
RTV Sealant 10 oz 005755F 005755F 005755F 005755F 005755F 005755F
11-M FiberFrax Strip Insulation 1" Wide 008473F 008473F 008473F 008473F 008473F 008473F
12-M Flue Exhaust Flange Seal Gasket 012907F 012907F 009734F 009734F 009734F 009735F
13-M Flue Exhaust Adapter Seal Gasket 012908F 012908F 009737F 009737F 009737F 009738F
14-M Gas Manifold Grommet 3/4" NPT 010778F 010778F 010778F 010778F 010778F 010778F
15-M Touch-up Paint
Green 750125 750125 750125 750125 750125 750125
Dark Gray 750126 750126 750126 750126 750126 750126
Cool Dark Gray 750256 750256 750256 750256 750256 750256
Warm Dark Gray 750258 750258 750258 750258 750258 750258
16-M Wire Harness Cabinet
Units manufactured prior to 9/1/12 012909F 012909F 012909F 012909F 012909F 012909F
Units manufactured from 9/1/12 2 Stage Units 014294F 014294F 014294F 014294F 014294F 012909F
Units manufactured from 9/1/12 On/Off Units 016164F 016164F 016164F 016164F 016164F 016165F
Wire Harness Control Box 2 Stage Controls
Units manufactured prior to 9/1/12 012910F 012910F 012910F 012910F 012910F 012910F
Units manufactured from 9/1/12 014295F 014295F 014295F 014295F 014295F 012910F
Wire Harness Control Box On/Off Controls 015044F 015044F 015044F 015044F 015044F 015044F
17-M Indicator Lamp 011848F 011848F 011848F 011848F 011848F 011848F
18-M Plastic Handle 012681F 012681F 012681F 012681F 012681F 012681F
O OPTIONS
1-O Remote Sensor for Low Water Cut-Off 008063F 008063F 008063F 008063F 008063F 008063F
2-O Low Water Cut Off PC Board 007157F 007157F 007157F 007157F 007157F 007157F
3-O Reset/Test Switch for Low Water Cut Off 005641F 005641F 005641F 005641F 005641F 005641F
4-O Alarm Bell 3" 005642F 005642F 005642F 005642F 005642F 005642F
Alarm Bell 4" 005643F 005643F 005643F 005643F 005643F 005643F
5-O Silencer/Reset Switch (Alarm) 005641F 005641F 005641F 005641F 005641F 005641F
P PUMPS*
1-P Pump Inline BR Soft 0010 012911F 012911F 012911F 012911F 012911F 012911F
Pump Inline SS/BR Medium 0012 012912F 012912F 012912F 012912F 012912F 012912F
Pump Inline BR Hard 1611 007226F 007226F 007226F 007226F 007226F 007226F
Pump Inline CIBF Soft 0010 012913F 012913F 012913F 012913F 012913F 012913F
Pump Inline CIBF Medium 0012 N/A N/A N/A N/A N/A N/A
Pump Inline CIBF Hard 1611 007232F 007232F 007232F 007232F 007232F 007232F
Pump Inline SS Medium 0012 013425F 013425F 013425F 013425F 013425F 013425F
2-P Pump Cartridge 0010 015272F 015272F 015272F 015272F 015272F 015272F
Pump Cartridge 0012 016480F 016480F 016480F 016480F 016480F 016480F
3-P Pump Flange Gasket 0012 008747F 008747F 008747F 008747F 008747F 008747F
Pump Flange Gasket 1611 008749F 008749F 008749F 008749F 008749F 008749F
R REFRACTORY
1-R Refractory Kit (All Panels) 012993F 012994F 012995F 012996F 012997F 012998F
2-R Refractory Front Panel 012914F 012915F 012916F 012917F 012918F 012919F
3-R Refractory Blanket 012920F 012921F 012922F 012923F 012924F 012925F
* For individual pump parts see separate pump parts IPL 9300.100

49
 CALL
OUT DESCRIPTION HD101 HD151 HD201 HD251 HD301 HD401
S SHEETMETAL
1-S Jacket Top 012926F 012927F 012928F 012929F 012930F 012931F
2-S Vertical Cabinet Supports 012932F 012932F 012932F 012932F 012932F 012932F
3-S Cabinet Supports 012933F 012934F 012935F 012936F 012937F 012938F
4-S Jacket Front Panel
Green 012939F 012940F 012941F 012942F 012943F 012944F
Warm Dark Gray 014262F 014263F 014264F 014265F 014266F 014267F
5-S Jacket Rear Panel
Green 012945F 012946F 012947F 012948F 012949F 012950F
Cool Dark Gray 014268F 014269F 014270F 014271F 014272F 014273F
6-S Jacket Left Side Panel Front
Green 012951F 012951F 012951F 012951F 012951F 012951F
Cool Dark Gray 014274F 014274F 014274F 014274F 014274F 014274F
7-S Jacket Right Side Panel front
Green 012952F 012952F 012952F 012952F 012952F 012952F
Cool Dark Gray 014275F 014275F 014275F 014275F 014275F 014275F
8-S Jacket Side Panel Rear
Green 012953F 012953F 012953F 012953F 012953F 012953F
Cool Dark Gray 014276F 014276F 014276F 014276F 014276F 014276F
9-S Base Panel 012954F 012955F 012956F 012957F 012958F 012959F
10-S Front Combustion Chamber Panel 012960F 012961F 012962F 012963F 012964F 012965F
11-S Rear/Bottom Combustion Chamber Panel 012966F 012967F 012968F 012969F 012970F 012971F
12-S Combustion Chamber Top 012972F 012973F 012974F 012975F 012976F 012977F
13-S Filter Box 012978F 012978F 012978F 012978F 012978F 012978F
14-S Controller Mounting Bracket
B-26 thru B-28 012979F 012979F 012979F 012979F 012979F 012979F
B-42 014293F 014293F 014293F 014293F 014293F 014293F
15-S Access Panel Water Connections (All Panels)
Green 012980F 012980F 012980F 012980F 012980F 012980F
Cool Dark Gray 014277F 014277F 014277F 014277F 014277F 014277F
16-S Access Panel Filter
Green 012981F 012981F 012981F 012981F 012981F 012981F
Cool Dark Gray 014278F 014278F 014278F 014278F 014278F 014278F
17-S Access Panel Wiring Box
Green 012982F 012982F 012982F 012982F 012982F 012982F
Cool Dark Gray 014214F 014214F 014214F 014214F 014214F 014214F
18-S Flue Exhaust Gasket Retainer 012983F 012983F 010029F 010029F 010029F 010030F
19-S Pump Cover (Taco 0010) 013355F 013355F 013355F 013355F 013355F 013355F
Pump Cover (Taco 0012) 013371F 013371F 013371F 013371F 013371F 013371F
Pump Cover (Taco 1610) 012987F 012987F 012987F 012987F 012987F 012987F
20-S Intake Air Collar (Outside) 012988F 012988F 012988F 012988F 012988F 012988F
21-S Intake Air Collar (Inside) 012989F 012989F 012989F 012989F 012989F 012989F
22-S Intake Air Vent Hood
Green 012772 012772 012772 012772 012772 012772
Cool Dark Gray 014246F 014246F 014246F 014246F 014246F 014246F
24-S Manifold Plenum Cover Panels 016518F 016519F 016521F 016522F 016523F 016524F
23-S Access Panel Igniter/Flame Sensor N/A N/A 013345F 013345F 013345F 013345F
V VENTING
1-V Outdoor Stack 015445F 015445F 015446F 015446F 015446F 014622F
2-V D15 Vent Cap Horizontal Thru-the-Wall for Indoor Units 011712 011712 007000 007000 007000 006644
3-V D20 Vent Cap Vertical (Roof top only) for Indoor Units 010800 010800 010801 010801 010801 010802
4-V Flue Exhaust Adapter 012990F 012990F 012991F 012991F 012991F 012992F
5-V D16 Intake Air Elbow 006996 006996 006996 006996 006996 006996

Gas Conversions* HD101 HD151 HD201 HD251 HD301 HD401

Natural to Propane 013066F 013066F 013066F 013066F 013066F 013067F
Propane to Natural N/A N/A N/A N/A N/A N/A
*FOR GAS CONVERSIONS, PLEASE CONSULT THE FACTORY.

50
13. IMPORTANT INSTRUCTIONS FOR THE COMMONWEALTH
OF MASSACHUSETTS
The Commonwealth of Massachusetts requires compliance (b) EXEMPTIONS: The following equipment is exempt from
with regulation 248 CMR 4.00 and 5.00 for installation of 248 CMR 5.08(2)(a)1 through 4:
through – the – wall vented gas appliances as follows:
1. The equipment listed in Chapter 10 entitled “Equipment Not
(a) For all side wall horizontally vented gas fueled equipment Required To Be Vented” in the most current edition of NFPA
installed in every dwelling, building or structure used in whole 54 as adopted by the Board; and
or in part for residential purposes, including those owned
or operated by the Commonwealth and where the side wall 2. Product Approved side wall horizontally vented gas fueled
exhaust vent termination is less than seven (7) feet above equipment installed in a room or structure separate from the
finished grade in the area of the venting, including but not dwelling, building or structure used in whole or in part for res-
limited to decks and porches, the following requirements shall idential purposes.
be satisfied:
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. VENTING SYSTEM PROVIDED. When the manufacturer of
At the time of installation of the side wall horizontal vented Product Approved side wall horizontally vented gas equipment
gas fueled equipment, the installing plumber or gasfitter shall provides a venting system design or venting system compo-
observe that a hard wired carbon monoxide detector with an nents with the equipment, the instructions provided by the
alarm and battery back-up is installed on the floor level where manufacturer for installation of the equipment and the venting
the gas equipment is to be installed. In addition, the installing system shall include:
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed 1. Detailed instructions for the installation of the venting system
on each additional level of the dwelling, building or structure design or the venting system components; and
served by the side wall horizontal vented gas fueled equip-
ment. It shall be the responsibility of the property owner to 2. A complete parts list for the venting system design or venting
secure the services of qualified licensed professionals for the system.
installation of hard wired carbon monoxide detectors
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT
a. In the event that the side wall horizontally vented gas fueled VENTING SYSTEM NOT PROVIDED. When the manufacturer
equipment is installed in a crawl space or an attic, the hard of a Product Approved side wall horizontally vented gas fueled
wired carbon monoxide detector with alarm and battery back- equipment does not provide the parts for venting the flue
up may be installed on the next adjacent floor level. gases, but identifies “special venting systems”, the following
requirements shall be satisfied by the manufacturer:
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the owner 1. The referenced “special venting system” instructions shall
shall have a period of thirty (30) days to comply with the above be included with the appliance or equipment installation
requirements; provided, however, that during said thirty (30) instructions; and
day period, a battery operated carbon monoxide detector with
an alarm shall be installed. 2. The “special venting systems” shall be Product Approved by
the Board, and the instructions for that system shall include a
2. APPROVED CARBON MONOXIDE DETECTORS. Each parts list and detailed installation instructions.
carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL (e) A copy of all installation instructions for all Product
2034 listed and IAS certified. Approved side wall horizontally vented gas fueled equipment,
all venting instructions, all parts lists for venting instructions,
3. SIGNAGE. A metal or plastic identification plate shall be and/or all venting design instructions shall remain with the
permanently mounted to the exterior of the building at a appliance or equipment at the completion of the installation.
minimum height of eight (8) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented GAS PRESSURE SUPERVISION
gas fueled heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch in size, The Commonwealth of Massachusetts requires listed high and
“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL low gas pressure switches (manual reset) for any model with a
OBSTRUCTIONS”. maximum firing input greater than 1,000,000 Btu/Hr in accor-
dance with 248 CMR 7.04(11)(d).
4. INSPECTION. The state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall not A gas pressure regulator (field supplied) is required in the gas
approve the installation unless, upon inspection, the inspector train ahead of the heater, for heaters having input rates great-
observes carbon monoxide detectors and signage installed er than 1,000,000 Btu/Hr, in accordance with 248 CMR 7.04
in accordance with the provisions of 248 CMR 5.08(2)(a)1 Figure 3B requirements.
through 4.

51
 ISO 9001
REGISTERED QUALITY MANAGEMENT SYSTEM

Raypak, Inc. 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 www.raypak.com
www.raypak.com